2018-2020 Yamaha mt-07 CAP3

SWINGARM
EASso0a7
SWINGARM
Removing the swingarm
Order Job/Parts to remove Q'ty Remarks

Rear brake caliper/Rear brake hose guide/Rear
Refer to “REAR BRAKE” on page 4-46.
brake hose holder
Rear wheel Refer to “REAR WHEEL’ on page 4-23.
Refer to “REAR SHOCK ABSORBER
Relay arm ASSEMBLY’ on page 4-86.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-96.
Pivot shaft protector (left)
hs
f&/ ow); ho;—
mmff |
Pivot shaft protector (right)

Sidestand switch coupler
Sidestand
4-90
SWINGARM

5 Footrest assembly (left) 1
6 Pivot shaft nut 1
7 Washer 1
8 Pivot shaft 1
9 Swingarm 1
10 Footrest bracket (left) 1
11 Drive chain guide 1
12 Dust cover 2
13 Oil seal 2
14 Spacer 2
15 Oil seal 2
16 Bearing 3
4-91
SWINGARM

17 Connecting arm nut/bolt (frame side) 1/1
18 Connecting arm 1
19 Spacer 1
20 Oil seal 2
21 Bearing 2
4-92
SWINGARM
EASa0226 EWAIS?70
REMOVING THE SWINGARM

1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot
EWAIS120
shaft.
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Measure:
* Swingarm side play
¢ Swingarm vertical movement
a. Measure the tightening torque of the pivot 3. Wash:
shaft nut. e Pivot shaft
¢ Dust cover
Pivot shaft nut e Collar
oN 110 N-m (11 kgf-m, 81 Ib-ft) ¢ Bearing
e Washer
b. Check the swingarm side play “A” by mov-
ing the swingarm from side to side.
Recommended cleaning solvent
lf the swingarm has side-to-side play, check
Kerosene
the collars, bearings, and dust covers.
Check the swingarm vertical movement “B” 4. Check:
by moving the swingarm up and down. ¢ Dust cover “1”
lf the swingarm vertical movement is not e Oil seal “2”
smooth or if there is binding, check the pivot Damage/wear — Replace.
shaft, collars, bearings, and dust covers. ¢ Bearing “3”
Damage/pitting — Replace.
e Collar “4”
Damage/scratches —> Replace.
3. Remove:
¢ Swingarm
EASa0227
CHECKING THE SWINGARM EFAS31113
CHECKING THE CONNECTING ARM

1. Check:
1. Check:
¢ Swingarm
¢« Connecting arm
Bends/cracks/damage — Replace.
Damage/wear —> Replace.
2. Check:
2. Check:
¢ Pivot shaft
¢ Bearing
Roll the pivot shaft on a flat surface.
¢ Oil seal
Bends — Replace.
Damage/pitting > Replace.
4-93
SWINGARM
3. Check:
° Collar
Damage/scratches — Replace.
EAS31 114
INSTALLING THE CONNECTING ARM

1. Lubricate:
e Spacer
¢ Bearing
1 Recommended lubricant
Lithium-soap-based grease EAS30226
INSTALLING THE SWINGARM
2. Install: 1. Lubricate:
* Bearing “1” e Spacer
* Oil seal “2” [Naa ¢ Pivot shaft
(to the connecting arm “3”) ¢ Bearing
TIP
Recommended lubricant
When installing the oil seals to the connecting | Lithium-soap-based grease
arm, face the character stamp of the oil seals
outside. 2. Install:
¢ Bearing “1”
¢ Oil seal “2” TENT
(to the swingarm)
Re 2 2TKE
\ Installed depth “a”
Ac 5 B 3.0 mm (0.12 in)
Installed depth “b”
7 Vo 1.0 mm (0.04 in)
a tH Installed depth “c”
bee 1 HL 9.0 mm (0.35 in)
A. :;
Left side Installed depth “d”
B. Right side 15 mm (0.59 In)
TIP
Installed depth “a” Install the oil seals to the swingarm so that they
3.5—4.5 mm (0.14-0.18 in) are facing in the directions shown in the illustra-
Installed depth “b” tion.
8.0-9.0 mm (0.31-0.35 in)
3. Install:
* Spacer
¢« Connecting arm
¢ Connecting arm bolt “1”
¢ Connecting arm nut
Connecting arm nut (frame side)

52 N-m (5.2 kgf-m, 38 Ib-ft)
TIP
Align two flat sides “a” of the connecting arm bolt
with the projections “b” on the frame.
4-94
SWINGARM
=| 5-
“Ls
<«d
A. Left side
B. Right side
3. Adjust:
e Drive chain slack
Refer to “DRIVE CHAIN SLACK’ on page 3-
18.
Drive chain slack (Maintenance

stand)
56.0-61.0 mm (2.20—2.40 in)
Drive chain slack (Sidestand)
51.0-—56.0 mm (2.01-—2.20 in)
Limit
58.0 mm (2.28 in)
4-95
CHAIN DRIVE
EAS20008
CHAIN DRIVE
Removing the drive chain

Refer to “REAR SHOCK ABSORBER
Drive chain guard
ASSEMBLY” on page 4-86.
Pivot shaft protectors/sidestand Refer to “SWINGARM’” on page 4-90.
Shift rod locknut (shift arm side)
Go] hm) —
Shift rod locknut (shift pedal side) Left-hand threads

|
Shift rod
|fm
Shift rod joint

1) &)
Shift arm
Drive sprocket cover
@)
fm
“|
Drive chain guide

cm
4-96
CHAIN DRIVE
Removing the drive chain

8 Pivot shaft nut 1 Loosen.
9 Drive chain 1
10 Drive sprocket nut 1
11 Washer 1
12 Drive sprocket 1
4-97
CHAIN DRIVE
EAsa0229
REMOVING THE DRIVE CHAIN

1. Stand the vehicle on a level surface.
EWAIS120
Securely support the vehicle so that there is

no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
EAS31115
2. Remove: REMOVING THE DRIVE SPROCKET
© Drive chain “1” 1. Straighten the drive sprocket nut ribs “a”.
TIP
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket. Refer
to “DRIVE CHAIN SLACK?” on page 3-18.
a. Loosen the pivot shaft nut “2” so that the en-

gaged thread length on the pivot shaft “3” is
3—4 ridges.
ECA21200
NOTICE
Make sure that the pivot shaft nut does not 2. Loosen:
come off the pivot shaft. e Drive sprocket nut
b. Tap the pivot shaft nut to push the pivot TIP
shaft to the left. Loosen the drive sprocket nut while pressing the
brake pedal.
FASS0230
CHECKING THE DRIVE CHAIN

1. Measure:
e 15-link section “a” of the drive chain
Out of specification — Replace the drive
chain.
15-link length limit

239.3 mm (9.42 in)
a. Measure the length “b” between the inner

sides of the pins and the length “c” between
the outer sides of the pins on a 15-link sec-
tion of the drive chain as shown in the illus-
tration.
b. Calculate the length “a” of the 15-link sec-
tion of the drive chain using the following
formula.
Drive chain 15-link section length “a” =
d. Move the footrest bracket “5” rearward, and (length “b” between pin inner sides + length
then remove the drive chain. “c” between pin outer sides)/2
4-98
CHAIN DRIVE
EC AI4290
TIP
e When measuring a 15-link section of the drive a cle has a drive chain with
chain, make sure that the drive chain is taut. y
¢ Perform this procedure 2-3 times, at a different oe er iapartaiay lll ideal aa
location each time. plates. gh-p
water or air, steam, gasoline, certain sol-
vents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure meth-
123 4 5 6 1213141516 ods could force dirt or water into the drive
TtltloooUDU\oOUDLDULUL LL chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
(a(0) (09) (0 _o}fo_9) (O_o a) 0 damage the O-rings. Therefore, use only
“FF
kerosene to clean the drive chain.
¢ Do not soak the drive chain in kerosene for
a more than ten minutes, otherwise the O-
rings can be damaged.
2. Check: __ __
¢ Drive chain
Stiffness — Clean and lubricate or replace. ae,
eya
e 4. Check:
—
g
Cc) © O-ring “1”
rm Damage — Replace the drive chain.
3. Clean: e Drive chain roller “2”
¢ Drive chain Damage/wear —> Replace the drive chain.
a. Wipe the drive chain with a clean cloth. * Drive chain side plate "3"
b. Putthe drive chain in kerosene and remove Damage/wear/cracks — Replace the drive
any remaining dirt. chain.
c. Remove the drive chain from the kerosene
and completely dry it.
4-99
CHAIN DRIVE
FAS31116
INSTALLING THE DRIVE SPROCKET

1. Install:
e Drive sprocket “1”
¢ Washer “2”
¢ Drive sprocket nut “3” [XEWG
5. Lubricate:
\
TIP
XY Drive sprocket nut
95 N-m (9.5 kgf-m, 70 Ib-ft)
¢ While applying the rear brake, tighten the drive

© Drive chain
sprocket nut.
¢ Install washer with the “OUT” mark “a” facing
out.
Chain lubricant suitable for O-
ring chains ¢ Stake the drive sprocket nut at cutouts “b” in
the drive axle.
Easa0231
CHECKING THE DRIVE SPROCKET

1. Check:
¢ Drive sprocket
More than 1/4 tooth “a” wear > Replace the
drive chain sprocket, drive chain, and rear
wheel sprocket as a set.
Bent teeth > Replace the drive chain sprock-
et, drive chain, and rear wheel sprocket as a
set.
EFASW234
INSTALLING THE DRIVE CHAIN

1. Install:
e Drive chain “1”
TIP
Make sure that the drive chain is positioned
above the portion “a” of the footrest bracket “2”.
b. Correct
1. Drive chain roller

2. Drive sprocket
EASa02a2
CHECKING THE REAR WHEEL SPROCKET

Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-28.
EASS0233
2. Tighten:
CHECKING THE REAR WHEEL DRIVE HUB ¢ Footrest bracket bolt “1”
Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-27. Footrest bracket bolt
45 N-m (4.5 kgf-m, 33 Ib-ft)
LOCTITE®
4-100
CHAIN DRIVE
NY 6. Measure:
YY XOU GE ¢ Installed shift rod length “a” and “b”
= Ws Incorrect > Adjust.
) U A
: } ONG) Installed shift rod length
O 217.5—219.5 mm (8.56—8.64 in)
- @ Installed length “b”
35.0—36.0 mm (1.38—1.42 in)
3. Lubricate:
© Drive chain
' Chain lubricant suitable for O-
ring chains
4. Fit the space “a” between the side plates of

the drive chain “1” onto the rib “b” on the drive
chain guide “2”. 7. Adjust:
7 , ¢ Installed shift rod length
a. Loosen both locknuts “1”.
TIP
The shift rod locknut (shift pedal side) has left-
hand threads.
b. Turn the shift rod “2” to obtain the correct
shift pedal position.
5. Install:
¢ Shift arm “1”
¢ Shift rod joint
© Shift rod
¢ Shift rod locknut
TIP
Before installing, make sure to align the mark “a”
of the shift shaft with the punch mark “b” of the
shift arm. c. Tighten both locknuts.
TIP
\y Shift arm pinch bolt The shift rod locknut (shift pedal side) has left-
14. N-m (1.4 kgf-m, 10 Ib-ft) hand threads.
Shift rod locknut (shift arm side)

9 N-m (0.9 kgf-m, 6.6 lb-ft)
Shift rod locknut (shift pedal
side)
9 N-m (0.9 kgf-m, 6.6 Ib-ft)
Left-hand threads
4-101
CHAIN DRIVE
d. Make sure the installed shift rod length is

within specification. Make sure that the in-
stalled shift rod length is within specification
and that the angle between the shift arm
and the shift rod is 90°.
8. Adjust:
e Drive chain slack
Refer to“DRIVE CHAIN SLACK’ on page 3-
18.
Drive chain slack (Maintenance

stand)
56.0-61.0 mm (2.20—2.40 in)
Drive chain slack (Sidestand)
51.0-—56.0 mm (2.01-—2.20 in)
Limit
58.0 mm (2.28 in)
ECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
4-102
CHAIN DRIVE
4-103
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMG..............cccsseeeeeeeeeeseeeenees 5-1

ENGINE OIL LUBRICATION CHART ............ cece cece cece eeeee eee eee eeeeeeee ee DOT
LUBRICATION DIAGRAMS ..... oo. ce eee e cease eee eee e ee saa ea eeeeeaeaeeaeeeeeseaee
DMD
ENGINE INSPECTION ...........ccccccssescesceeceeee

cesses ceneeeeeseeeeeeaeeaseeseneaeeaeeseeeeaeeeenees 5-8
MEASURE THE COMPRESSION PRESSURE ....0... cee cee cece eee OG
ADJUSTING THE EXHAUST GAS VOLUME.. be eeaeeeeeeeseeseeeeeeeees
DOG
CHECKING THE CYLINDER HEAD BREATHER HOSE fb ddei dons eenetewsevnd ne!
FENAL ice cesieiiciceccesecsnndecesapsnvesuessansondenensdunsasemdnssdesuespeanenusensueuncs 5-11

REMOVING THE ENGINE ..... i.e cece cee ceeee cee eee tenses eeeeseeeeeeeeeeeteeeeeeee OTT
PS TALUS TPE ENGIN ose occ ees eve cces cones iececes eecnsaen cconcass eevee sees nee
PSURFi vesine ct case ties Sw esone see encte dee paes bamee dee eave sees duwtuose fuawdecnsiaeudasanuansaees 5-20
REMOVING THE CAMSHAFTS... peenee secede snenecesnnenseessecnnensseesesnesesnesene TE
CHECKING THE CAMSHAFTS .. gesb eau sta eceeeddsvedes sabes wvesnew eid
CHECKING THE CAMSHAFT SPROCKETS .. bese eteeeeeeeeeeteeeeeseeeeesD"2O
CHECKING THE TIMING CHAIN TENSIONER. .cssssssssssessssssvssesesseseseeeees5-26
CHECKING THE DECOMPRESSION SYSTEM........... eee B27
INSTALLING THE CAMSHAFTS .. se naaeeeeeesecaaeaeneeeseesseeeseeees OUOT
INSTALLING THE CYLINDER HEAD COVER .. ciiduaieeseenaetissivessus
Cae rr its sects rasue te seeececeeen saeepanseanae den uavinsaeduntuose teawdecusieudesineuansanen 5-32
REMOVING THE CYLINDER HEAD. ....0 20... ee cece ee eee eee GB
CHECKING THE TIMING CHAIN GUIDES. ............ eee eee rere renee DO
CHECKING THE CYLINDER HEAD... oo. ceee ccc cece cece cece eee ee eee DOGO
INSTALLING THE CYLINDER HEAD ...0.. occ cece eee eeeeee eee eeeeteeeeee ee OOOT
VALVES AND VALVE SPRINGG...........ssscssssssssssssessccnscecsessesccecnessesssscansssenes 5-38

REMOVING THE VALVES.. ve aeeeeeeeeesaneeeeeeessaeeeeees OOD
CHECKING THE VALVES AND VALVE GUIDES .. pisdecdschuciees oo stsee see
CHECKING THE VALVE SEATS voccccccsccsssssssssssssssssssvsesessssesssssssssssssesssns 541
CHECKING THE VALVE SPRINGS......0..000.. cc ceeeee eee cece eee eeeeeteeeee eee eeee DAD
CHECKING THE VALVE LIFTERS .......... cee ceeee cee cenee eee eaesaeeeeeeeaeaeees DAG
INSTALLING THE VALVES 00000... e ccc eee e eee eenee cee ees nner eeeeee teeters es DAG
GENERATOR AND STARTER CLUTCH..............ccccsccssenseeseeesenseeeaseaaeneeneaes 5-45

REMOVING THE: GENERATOR ...:.::0cc0ccccccccccsieiicsccssnecicesetees siete sectcnsetees OO
REMOVING THE STARTER CLUTCH ...... cece ccc eee eeeeeeeeeeeeeeeeees DAB
CHECKING THE STARTER CLUTCH ....0 lee eee eee eeeeee eee eee eee DAB
CHECKING THE TORQUE LIMITER .......... cece cee ceececee eee eeesu tenses eaeaaeee DAY
INSTALLING THE STARTER CLUTCH ....00..... eee eee c cece eeeeee eee DAY
INSTALLING THE GENERATOR.............ccccecccceceeeee
teens ceeseasaeeeseesasaaeeeeeees DOAY
ELECTRIC STARTER .. uu... cccsscceceseeeeeceeeneeeceeeneeeseeeaaeeseaenaesseeeeaeeeeaeeaeeseaseaes 5-51
CHECKING THE STARTER MOTOR ...... 0... e eee eee DDG
ASSEMBLING THE STARTER MOTOR .......0.....0.ceeccececee eee ce eee e terete eee DUDA
INSTALLING THE STARTER MOTOR 11.0.0... cece eee e eee e eee eeeeee eee OOF
TGA setsits oc sits pet scetcees esta nid nasiedarretem ge ou adienna wun enw seuisee cudaguddaddecbanueauauesdeassaenadanes 5-55
REMOVING THE CLUTCH... eines nase Giasessiensingssensshaendasaddndsenssasd SOE)
CHECKING THE FRICTION PLATES... fiat 6s Went conch wenden eaddessnFaceaud =U)
CHECKING THE CLUTCH PLATES -cccccssssssssssssssssssssvsssssesesssssessessesssssses 5-80
CHECKING THE CLUTCH SPRINGS....0000. eee cece eee eeee eee 9°60
CHECKING THE CLUTCH HOUSING 1.0. eee e cette eee ee eee DOT
CHECKING THE CLUTCH BOSS ...00 0. e eee cee eeee eee eeeeeeeee eens O61
CHECKING THE PRESSURE PLATE ....0... eee ceececeecee cee eeeeeeeeeeeseeeeee OPOT
CHECKING THE PRIMARY DRIVE GEAR.. isdasfiwiscekuavaeealdaniaveccdenet =O) |
CHECKING THE PRIMARY DRIVEN GEAR. seerserecsacseesenses TO |
CHECKING THE PULL LEVER SHAFT AND PULL ROD seveddawed festa iets Oe
INSTALLING THE CLUTCH...0. 2... e cece cee eee e ee eee cent eeeeeaeeeeeeee es DO2
SHIFT SHAFT. ........cccccssssecccssecsscsnssessccaneessccnssscncnnesseseneaseescsnesessocnaecesosaceeseseas 5-65

CHECKING THE SHIFT SHAPT 0.2... cccesceceeceecneeeeeeseeseeeeeeseseeeeeees DOL
CHECKING THE STOPPER LEVER.....00.0. cece ececeeec cece eee e eee eee eee 67
INSTALLING THE SHIFT SHAPT ..... 0... cece cece ee eee teens eee eeaeeeeeee es DOL
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CHECKING THE SPROCKET AND CHAIN... eee eee OO
CHECKING THE OIL PUMP 1.0.02... eee cece eee eeenene ee eeeceeeeeeeeeecaeeeeeeeeeeees DO7O
CHECKING THE RELIEF VALVE ...... eee e cect cece sees sae eeeeeeeeeae eee OO
ASSEMBLING THE OIL PUMP. .....0.. 00... cee cece cena eeeee eee eeeeeeeeeeeees DVO
INSTALLING THE OIL PUMP. ..... 2.0... cece ecce cence seeeneeeceeeeeeneeeseeesseeseeeeeeee Dol I
PU PI oa scceie ce vanaeveseeaunsetindseacdocecunducesnscssauccestausawseuentaduussdeudiidadacaceadsdadanaecsase 5-72

REMOVING THE OIL PAN, ...ccicisccscccssencsveescestncesiectetenestcers contedseeerteeseneee PP
CHECKING THE OIL STRAINER ..... ooo ee eee eeeeeeee eee DOV
INSTALLING THE OIL PAN ..0. 0... ice ceecee cence eee eeeene ee eeeseesaseaeeesessasaeeeeeeees DOT
PENG ais oststie reise ence ve wes eerseeseseawademssenaetenseenanenssuecessadeuseuessresuueassanendenes 5-74

DISASSEMBLING THE CRANKCASE .............cccccceeececceeeeeeeteeeeeeeeeeeeeeeees O78
CHECKING THE CRANKCASE .. jipdamesndig depcnaeechad tune deentensseesdeedeeeseeeee
=O
ASSEMBLING THE CRANKCASE... pedacwadees sivevenvuidaviedisteniersecgler
INSTALLING THE OIL PRESSURE SWITCH... vee eeteeeeeeetesaeeeeeeeeeeees
OVO
CONNECTING RODS AND PISTONS. ..........cccccscescssnseeseensaeeeeeeseeseeeaeeneesenneas 5-80

REMOVING THE CONNECTING RODS AND PISTONS.......................5-82
CHECKING THE CYLINDER AND PISTON ........ cee cere eee DB2
CHECKING THE PISTON RINGS..... 0... ee ce ceecee cece eeeeeeeeeeeceeeeeeeeeeeeees DOGG
CHECKING THE PISTON PIN.. dive Gdeipsaddwdeaetdsiptnetacvesuceieiensdiia; OCF
CHECKING THE CONNECTING RODS... bet eateeeeeeeeeeteeeee OBA
INSTALLING THE CONNECTING ROD AND PISTON .. pedeeisewes tewea teaver eRe
CRANKSHAFT AND BALANCER SHAFT
REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ..............
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......0.000000002..
CHECKING THE BALANCER SHAFT ASSEMBLY ............. ee
CHECKING THE CRANKSHAFT..
INSTALLING THE CRAN KSHAFT..
INSTALLING THE BALANCER SHAFT ASSEMBLY...
TRANSMISSION
REMOVING THE TRANSMISSION ..
CHECKING THE SHIFT FORKS...
CHECKING THE SHIFT DRUM ASSEMBLY...
CHECKING THE TRANSMISSION..
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE...
INSTALLING THE TRANSMISSION idanaeuisenmmaseenae
LUBRICATION SYSTEM CHART AND DIAGRAMS
EASs20298

EASS2 262
ENGINE OIL LUBRICATION CHART

13 Ss
12 :
=
mo |ly A.
| a i
—l
—_]
iS
Oil strainer
co ONOahrwNY=
Oil pump
Relief valve
Oil cooler
Oil filter cartridge
Main gallery
Oil pressure switch
Crankshaft
Oil nozzle
10. Balancer shaft assembly
11. Timing chain tensioner
12. Intake camshaft
13. Exhaust camshaft
14. Main axle
15. Drive axle
o-1
EASa2 383
LUBRICATION DIAGRAMS
Crankcase, cylinder, and cylinder head (right side view)
Timing chain tensioner

CANOahah =
Intake camshaft
Exhaust camshaft
Crankshaft
Oil cooler
Oil drain bolt
Oil strainer
Oil pump
Crankcase and cylinder (left side view)
Crankshaft
akon=
Balancer shaft assembly

Connecting rod
Oil cooler
Oil pump (bottom view)
Oil pump
akon=
Oil pressure switch

Oil cooler
Oil strainer
5-4
Camshaft (top view)
1. Intake camshaft
2. Cylinder head
3. Exhaust camshaft
Crankshaft (front view)
Oil nozzle
oh =
Piston
Crankshaft
Main gallery
Crankshaft and transmission (top view)
Balancer shaft assembly

oh =
Crankshaft
Main axle
Drive axle
ENGINE INSPECTION
Eas20041
¢« Compression gauge “2”
ENGINE INSPECTION
EAS30249
Compression gauge extension
MEASURE THE COMPRESSION PRESSURE 122mm
The following procedure applies to all of the cyl- 90890-04136
inders. Compression gauge extension
122mm
TIP
YM-04136
Insufficient compression pressure will result ina Compression gauge
loss of performance. 90890-03081
Engine compression tester
1. Measure:
YU-33223
* Valve clearance
Out of specification — Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-6.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
¢ Passenger seat
¢ Rider seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
¢ Air scoop (left) 8. Measure:
e Air scoop (right) ¢« Compression pressure
¢ Fuel tank center cover (fuel tank side covers) Out of specification — Refer to steps (c) and
Refer to “GENERAL CHASSIS (4)” on (d).
page 4-9. TIP
* Fuel tank Due to the engine characteristics, the compres-
Refer to “FUEL TANK” on page 7-1. sion pressure is different for cylinder #1 and cyl-
4. Disconnect: inder #2.
* Ignition coil coupler “1”
5. Remove:
* Ignition coil “2” Compression pressure
765-985 kPa/355 r/min (7.7-9.9
a kgf/cm?/355 r/min, 108.9—140.2
oN psi/355 r/min)
Sex
BU,
red
Compression pressure (#2 cylin-
oc Ho
der)
687-884 kPa/355 r/min (6.9-8.8
kgf/cm2/355 r/min, 97.8—125.8
psi/355 r/min)
N
a. Turn the main switch to “ON”.
b. With the throttle wide open, crank the en-
6. Remove:
gine until the reading on the compression
¢ Spark plug
ECA13340 gauge stabilizes.
NOTICE
EWA12940
Before removing the spark plugs, use com-

To prevent sparking, ground all spark plug
pressed air to blow away any dirt accumulat-
leads before cranking the engine.
ed in the spark plug wells to prevent it from
falling into the cylinders.
7. Install:
° Extension “1”
ENGINE INSPECTION
FASS1132
TIP
ADJUSTING THE EXHAUST GAS VOLUME
The difference in compression pressure be-
TIP
tween cylinders should not exceed 100 kPa (1
¢ Be sure to set the CO density level to standard,
kg/cm?, 14 psi).
and then adjust the exhaust gas volume.
c. If the compression pressure is above the * To adjust the exhaust gas volume, use the CO
maximum specification, check the cylinder adjustment mode of the Yamaha diagnostic
head, valve surfaces and piston crown for tool. For more information, refer to the opera-
carbon deposits. tion manual of the Yamaha diagnostic tool.
Carbon deposits —> Eliminate.
1. Connect the Yamaha diagnostic tool to the
lf the compression pressure is below the
coupler. For information about connecting the
minimum specification, pour a teaspoonful
Yamaha diagnostic tool, refer to “YAMAHA
of engine oil into the spark plug bore and
DIAGNOSTIC TOOL’ on page 8-36.
measure again.
F-
Refer to the following table.
Yamaha diagnostic tool USB
Compression pressure (with oil applied into 90890-03257
the cylinder) Yamaha diagnostic tool (A/I)
Reading Diagnosis 90890-03262
Higher than without | Piston ring(s) wear or FASS31133
oil damage —> Repair. CHECKING THE CYLINDER HEAD
Same as without oil Pistons, valves, cylin- BREATHER HOSE
der head gasket or 1. Remove:
piston ring(s) possibly ¢« Passenger seat
defective — Repair. e Rider seat
page 4-1.
9. Install:
¢ Air scoop (left)
¢ Spark plug
e Air scoop (right)
* Ignition coil
¢ Fuel tank center cover (fuel tank side covers)
Spark plug
page 4-9.
13 N-m (1.3 kgf-m, 9.6 Ib-ft)
e Fuel tank
10.Connect: Refer to “FUEL TANK” on page 7-1.
* Ignition coil coupler 2. Check:
11.Install: e Cylinder head breather hose “1”
¢ Fuel tank Cracks/damage —> Replace.
Refer to “FUEL TANK” on page 7-1. Loose connection — Connect properly.
ECA14920
NOTICE
¢ Air scoop (right)
e Air scoop (left) Make sure the cylinder head breather hose is
Refer to “GENERAL CHASSIS (4)” on routed correctly.
page 4-9.
¢ Rider seat
¢ Passenger seat
page 4-1.
ENGINE INSPECTION
3. Install:
¢ Fuel tank
Refer to “FUEL TANK” on page 7-1.
* Air scoop (right)
e Air scoop (left)
page 4-9.
e Rider seat
¢ Passenger seat
page 4-1.
9-10
ENGINE REMOVAL
EASsO042
ENGINE REMOVAL
Removing the muffler and exhaust pipe

Pivot shaft protector (right) Refer to “SWINGARM’” on page 4-90.
Footrest assembly (right) Refer to “REAR BRAKE” on page 4-46.
1 O. sensor coupler 1 Disconnect.
2 Muffler assembly 1
3 Exhaust gasket 2
4q Muffler bracket 2
5 Muffler cover 1
6 O, sensor { Remove the O, sensor only when neces-
sary.
5-11
ENGINE REMOVAL
Disconnecting the leads and hoses
Order Job/Parts to remove Remarks

Rider seat/Passenger seat
page 4-1.
Pivot shaft protectors/Sidestand/Footrest
Refer to “SWINGARM” on page 4-90.
assembly (left)
Brake fluid reservoir/Footrest assembly (right) Refer to “REAR BRAKE” on page 4-46.
Air scoop (left)/Air scoop (right)/Fuel tank center Refer to “GENERAL CHASSIS (4)” on
cover (fuel tank side covers) page 4-9.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air duct bracket Refer to “AIR FILTER” on page 7-7.
Throttle bodies/Air filter case/Cylinder head Refer to “THROTTLE BODIES” on page 7-8.
breather hose
9-12
ENGINE REMOVAL

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-25.
Radiator/Coolant reservoir Refer to “RADIATOR” on page 6-2.
Oil cooler outlet hose/Oil cooler inlet hose Refer to “OIL COOLER’ on page 6-5.
Water pump inlet pipe/Water pump outlet pipe Refer to “WATER PUMP” on page 6-10.
Drive chain/Drive sprocket Refer to “CHAIN DRIVE” on page 4-96.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL’ on
page 3-22.
1 Clutch cable 1 Disconnect.
2 Negative battery lead 1 Disconnect.
9-13
ENGINE REMOVAL

3 Fuel tank overflow hose 1
4 Fuel tank breather hose 1 Except for California.
5 Canister breather hose 1 For California only.
6 Sidestand switch coupler 1 Disconnect.
7 Engine ground lead 2 Disconnect.
8 Gear position switch coupler 1 Disconnect.
9 Starter motor lead 1 Disconnect.
10 Coolant temperature sensor coupler 1 Disconnect.
11 Stator coil coupler 1 Disconnect.
12 Crankshaft position sensor coupler 1 Disconnect.
13 Ignition coil coupler 2 Disconnect.
14 Oil pressure switch connector 1 Disconnect.
5-14
ENGINE REMOVAL
Removing the engine

1 Clutch cable guide 1
2 Rear brake hose joint bracket bolt 1
Rear shock absorber assembly bolt/nut (front
3
side)
4 Spacer
5 Pivot shaft nut Loosen.
6 Engine bracket bolt (left)

7 Engine mounting bolt (left upper side)
8 Engine bracket (left)
9 Engine bracket bolt (right)
10 Engine mounting bolt (right upper side)
11 Engine bracket (right)
9-15
ENGINE REMOVAL
Removing the engine
-
=
w
|
Zt
#
_A
YS
—_—
| 13
a a

12 Engine mounting bolt (right front side) 1
13 Engine mounting bolt (left front side) 1
14 Engine mounting bolt/nut (rear lower side) 1/1
15 Engine mounting bolt/nut (rear upper side) 1/1
16 Engine 1
17 | Plat a
0-16
ENGINE REMOVAL
EAS30250 EC A211 81
REMOVING THE ENGINE NOTICE

TIP Do not move the rear brake hose joint brack-
Pass a suitable rod “1” through the holes in the et more than necessary. Otherwise, the
brackets of the passenger footrests “2” and se- brake hoses could bend and break.
cure the rod to support the vehicle.
AUS
\ AN
SALES
SS
EFAS30251
INSTALLING THE ENGINE

¢ Engine mounting bolt (rear lower side) “1” 1. Install: (for models with a stamped “1” mark
a. Loosen the pivot shaft nut “2”, and then re- on the frame)
move the footrest bracket bolts “3”. e Plate “1”
TIP
¢ Install the plate only for frames that have a
stamped “1” mark at the location “a”.
¢ Fit the projections “b” on the plate into the slots
“c’ in the frame.
A. Left side
B. Right side
b. Move the footrest bracket “4” rearward, and
then loosen the engine mounting bolt (rear
lower side).
2. Install:
e Engine “2”
3. Install:
¢ Engine mounting bolt (rear upper side) “3”
e Engine mounting nut (rear upper side) “4”
e Engine mounting bolt (rear lower side) “5”
e Engine mounting nut (rear lower side) “6”
e Engine mounting bolt (left front side) “7”
e Engine mounting bolt (right front side) “8”
e Engine mounting bolt (right upper side) “9”
2. Remove: e Engine bracket bolt (right) “10”
* Engine mounting bolt (rear upper side) “1” ¢ Engine bracket (right) “11”
a. Remove the rear brake hose joint bracket TIP
bolt “2”. Temporarily tighten the bolts and nuts.
b. Move the rear brake hose joint bracket “3”
slightly rearward, and then remove the en-
gine mounting bolt (rear upper side).
9-17
ENGINE REMOVAL
4. Tighten:
¢ Engine mounting nut (rear upper side) “4”
¢ Engine mounting nut (rear lower side) “6”
¢ Engine mounting bolt (left front side) “7”
Engine mounting nut (rear upper

side)
55 N-m (5.5 kgf-m, 41 Ib-ft)
Engine mounting nut (rear lower
side)
55 N-m (5.5 kgf-m, 41 Ib-ft)
Engine mounting bolt (left front
side)
75 N-m (7.5 kgf-m, 55 Ib-ft)
5. Install:
¢ Engine mounting bolt (left upper side) “12
¢ Engine bracket bolt (left) “13”
¢ Engine bracket (left) “14”
TIP
Temporarily tignten the bolts.
7. Install:
6. Tighten:
¢ Rear brake hose joint bracket “1”
* Engine mounting bolt (left upper side) “12”
¢ Rear brake hose joint bracket bolt “2”
¢ Engine mounting bolt (right front side) “8”
¢ Engine mounting bolt (right upper side) “9”
Rear brake hose joint bracket
* Engine bracket bolt (right) “10” bolt
¢ Engine bracket bolt (left) “13” 7 N-m (0.7 kgf-m, 5.2 Ib-ft)
Yy | Engine mounting bolt (left upper TIP
ON side) Make sure that the rear brake hose joint bracket
55 N-m (5.5 kgf-m, 41 Ib-ft)
contacts the projection “a” on the frame.
Engine mounting bolt (right front
side)
NE NOVZ ,
uy
75 N-m (7.5 kgf-m, 55 Ib-ft)
Engine mounting bolt (right up-
per side)
55 N-m (5.5 kgf-m, 41 Ib-ft)
E
| A
WE 6
Engine bracket bolt (right)
hy
25 N-m (2.5 kgf-m, 18 Ib-ft)
Engine bracket bolt (left)
25 N-m (2.5 kgf-m, 18 Ib-ft)
8. Install:
e Clutch cable guide “1”
Clutch cable guide bolt

ay 7 N-m (0.7 kgf-m, 5.2 lb-ft)
TIP
Make sure that the projection “a” on the clutch
cable guide contacts the frame.
0-18
ENGINE REMOVAL
9-19
CAMSHAFTS
EASZO043
CAMSHAFTS
Removing the cylinder head cover

Rider seat/passenger seat
page 4-1.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-25.
Radiator inlet hose/Radiator Refer to “RADIATOR?” on page 6-2.
Clutch cable guide Refer to “ENGINE REMOVAL’ on page 5-11.
Cylinder head breather hose Disconnect.
9-20
CAMSHAFTS
Removing the cylinder head cover

Ignition coil coupler Disconnect.
Ignition coil
©
Spark plug
&!|
om)
Cylinder head cover

om)
Cylinder head cover gasket

S|
Breather plate
Breather plate gasket
co);
a
Oo}
Timing chain guide (upper side)
5-21
CAMSHAFTS
Removing the camshafts
GOS

Crankshaft end cover
—.
Timing mark accessing bolt

©! Po
Timing chain tensioner

Timing chain tensioner gasket
om] &/}
Intake camshaft cap

Exhaust camshaft cap
oO; oO); ~s| @)
Dowel pin
Intake camshaft
Exhaust camshaft
Intake camshaft sprocket
—k
©
Exhaust camshaft sprocket

=k.
ol,
9-22
CAMSHAFTS
Removing the camshafts
GOS

12 Decompressor lever #2 1
13 Decompressor lever #1 1
14 Decompressor lever pin 2
9-23
CAMSHAFTS
EASS0256
REMOVING THE CAMSHAFTS NOTICE

1. Remove: To prevent damage to the cylinder head,
¢ Crankshaft end cover “1” camshafts or camshaft caps, loosen the
¢ Timing mark accessing bolt “2” camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
| LA
2. Align:
¢ Mark “a” on the generator rotor
(with the slot “b” in the generator rotor cover) 5. Remove:
a. Turn the crankshaft counterclockwise. e Intake camshaft “1”
b. When piston #1 is at TDC on the exhaust e Exhaust camshaft “2”
stroke, align the TDC mark “a” on the gen- TIP
erator rotor with the slot “b” in the generator To prevent the timing chain from falling into the
rotor cover. crankcase, fasten it with a wire “3”.
NWA
N
eciop
3. Remove: 6. Remove:
¢ Timing chain tensioner “1” e Intake camshaft sprocket “1”
¢ Timing chain tensioner gasket
TIP
a. Insert the hexagon wrench “2” (part No.: While holding the intake camshaft sprocket with
1WS-12228-00) into the timing chain ten- the rotor holding tool “2”, loosen the intake cam-
sioner. shaft sprocket bolts.
. Remove the timing chain tensioner.
2
SO) — 1
F- Rotor holding tool
90890-01235
Universal magneto and rotor
holder
YU-01235
4. Remove:
Be /
¢ Intake camshaft cap “1”
¢ Exhaust camshaft cap “2”
9-24
CAMSHAFTS
7. Remove: 3. Measure:
¢ Exhaust camshaft sprocket “1” ¢ Camshaft runout
TIP Out of specification + Replace.
While holding the exhaust camshaft with a suit-
able tool, loosen the exhaust camshaft sprocket Camshaft runout limit
bolts. 0.030 mm (0.0012 in)
= b
| J ai
4. Measure:
EAS30257
CHECKING THE CAMSHAFTS ¢ Camshaft-journal-to-camshaft-cap clearance

1. Check: Out of specification + Measure the camshaft
¢ Camshaft lobe
journal diameter.
Blue discoloration/pitting/scratches —> Re-
place the camshaft. Camshaft-journal-to-camshaft-
cap clearance
2. Measure:
0.028—0.062 mm (0.0011-—0.0024
e Camshaft lobe dimension “a”
in)
Out of specification + Replace the camshaft.
a. Install the camshafts into the cylinder head
Camshaft lobe dimensions
(without the camshaft caps).
Lobe height (Intake)
b. Position a strip of Plastigauge® “1” onto the
35.610—35.710 mm (1.4020—
camshaft journal as shown.
1.4059 in)
Limit
35.510 mm (1.3980 in)
Lobe height (Exhaust)
35.710-—35.810 mm (1.4059—
1.4098 in)
Limit
35.610 mm (1.4020 in)
# ee
c. Install the dowel pins and camshaft caps.
9-25
CAMSHAFTS
TIP
e Tighten the camshaft cap bolts in stages and in 4 1
a crisscross pattern, working from the inner
caps out.
e Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
Exhaust camshaft cap bolt

10 N-m (1.0 kgf-m, 7.4 Ib-ft) 1/4 tooth
Intake camshaft cap bolt Correct
o
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
. Timing chain
=
d. Remove the camshaft caps, and then mea- 2. Camshaft sprocket
sure the width of the Plastigauge® “1”. EAS S0266
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
¢ Timing chain tensioner
Cracks/damage/rough movement —> Re-
place.
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
TIP
While pressing the timing chain tensioner rod,
5. Measure: . | wind it counterclockwise with a hexagon wrench
¢ Camshaft journal diameter “a” “4” (Parts No.: 1WS-12228-00) until it stops.
Out of specification + Replace the camshaft.
Within specification —+ Replace the cylinder
head and camshaft caps as a set.
Camshaft journal diameter

21.959-—21.972 mm (0.8645-—
0.8650 in)
b. Make sure that the timing chain tensioner

rod moves in and out of the timing chain
tensioner housing smoothly. If there is
rough movement, replace the timing chain
tensioner.
EAS30936
CHECKING THE CAMSHAFT SPROCKETS

1. Check:
¢ Camshaft sprocket
More than 1/4 tooth wear “a” — Replace the
camshaft sprockets and timing chain as a set.
9-26
CAMSHAFTS
camshaft sprocket bolts in the proper tighten-

EASSO287
CHECKING THE DECOMPRESSION SYSTEM ing sequence as shown.

1. Check:
f-
« Decompression system Rotor holding tool
TIP 90890-01235
e Check that the decompressor lever pins “1” Universal magneto and rotor
projects from the camshaft. holder
e Check that the decompressor cams “2” and de- YU-01235
compressor lever pins “1” moves smoothly.
EAS30269
INSTALLING THE CAMSHAFTS

1. Align:
¢ Mark “a” on the generator rotor
(with the slot “b” in the generator rotor cover)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC, align the TDC
mark “a” on the generator rotor with the slot
“b” in the generator rotor cover. 3. Install:
¢« Decompressor lever pin “1”
¢ Decompressor lever #1 “2”
e Decompressor lever #2 “3”
TIP
¢ Face the cutout “a” in each decompressor le-
ver pin toward the exhaust camshaft sprocket.
¢ Install the decompressor lever pins, decom-
pressor lever #1, and decompressor lever #2
into the exhaust camshaft as shown in the illus-
tration.
2. Install:
% nf Sl
¢ Intake camshaft sprocket “1”
i1@- 2 1
S Intake camshaft sprocket bolt |
24 N-m (2.4 kgf-m, 18 lb-ft) i
i
TIP
oO} ©
e Make sure that the marks “a” on the intake
camshaft sprocket are aligned with cam lobe
#1 “b” as shown in the illustration.
¢ While holding the intake camshaft sprocket
with the rotor holding tool “2”, tighten the intake
9-27
CAMSHAFTS
4. Install: TIP
¢ Exhaust camshaft sprocket “1” ¢ When installing the timing chain, start with the
exhaust camshaft and be sure to keep the tim-
YX Exhaust camshaft sprocket bolt ing chain as tight as possible on the exhaust
% 24 N-m (2.4 kgf-m, 18 Ib-ft) side.
¢ Make sure that the match marks “a” on the ex-
TIP
haust camshaft sprocket and cam lobe #1 “b”
e Make sure that the mark “a” on the exhaust are aligned with the cylinder head edge “c” as
camshaft sprocket is aligned with cam lobe #1 shown in the illustration.
“b” as shown in the illustration. ¢« Temporarily tighten the exhaust camshaft cap
¢ While holding the exhaust camshaft with a suit- bolts, and then tighten the bolts to specification
able tool, tighten the exhaust camshaft sprock- in a crisscross pattern.
et bolts.
h
e Tighten the camshaft sprocket bolts in the
tightening sequence as shown. Exhaust camshaft cap bolt
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
6. Install:
¢ Timing chain “1”
(onto the intake camshaft sprocket “2”)
e Intake camshaft
e Intake camshaft cap
EC A20930
NOTICE
¢ Lubricate the camshaft cap bolts with the
engine oil.
5. Install: ¢ The camshaft cap bolts must be tightened
¢ Timing chain “1” evenly or damage to the cylinder head,
(onto the exhaust camshaft sprocket “2”) camshaft caps, and camshafts will result.
¢ Exhaust camshaft ¢ Do not turn the crankshaft when installing
¢ Exhaust camshaft cap the camshaft to avoid damage or improper
ECA20930
valve timing.
NOTICE
¢ Lubricate the camshaft cap bolts with the a. Install the timing chain onto intake camshaft
engine oil. sprocket, and then install the intake cam-
¢ The camshaft cap bolts must be tightened shaft onto the cylinder head.
evenly or damage to the cylinder head, TIP
camshaft caps, and camshafts will result. Make sure the match mark “a” on the intake
¢ Do not turn the crankshaft when installing camshaft sprocket is aligned with the cylinder
the camshaft to avoid damage or improper head edge “b”.
valve timing.
0-28
CAMSHAFTS
c. Install a new timing chain tensioner gasket

“3”, the timing chain tensioner “4”, and the
timing chain tensioner bolts “5” on the cylin-
der block.
TIP
Be sure to install the timing chain tensioner gas-
ket so that the portion “a” of the gasket is pro-
truding from the upper inner side of the timing
chain tensioner.
b. Tighten the intake camshaft cap bolts.
TIP
Temporarily tighten the intake camshaft cap
bolts, and then tighten the bolts to specification
in a crisscross pattern.
Intake camshaft cap bolt

> 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
7. Install: d. Tighten the timing chain tensioner bolts to
* Timing chain tensioner specification.
* Timing chain tensioner gasket KEG
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the timing chain
tensioner rod fully counterclockwise with a e. Screw the hexagon wrench by hand until
hexagon wrench “1”. the timing chain tensioner rod touches the
timing chain guide, and then tighten 1/4 turn
by tool.
TIP
The timing chain tensioner rod is extended by
turning the hexagon wrench clockwise.
Keep pressing the timing chain tensioner

rod by hand, remove the hexagon wrench,
and then insert the hexagon wrench “2”
(Parts No.: 1WS-12228-00) into the timing
chain tensioner rod.
f. Remove the hexagon wrench.

g. Install the timing chain tensioner cap bolt
and gasket, and then tighten the timing
chain tensioner cap bolt to specification.
Timing chain tensioner cap bolt

Q) 7 N-m (0.7 kgf-m, 5.2 lb-ft)
9-29
CAMSHAFTS
8. Turn:
¢ Crankshaft
2. OD
(several turns counterclockwise)
9. Check:
¢ Mark “a”
Make sure the mark “a” on the generator rotor
is aligned with the slot “b” in the generator ro-
tor cover. QD
¢ Camshaft sprocket match mark
Make sure the match marks “c” on the cam- Pi LA
shaft sprockets are aligned with the cylinder
INSTALLING THE CYLINDER HEAD COVER
head mating surface “d”.
1. Install:
Out of alignment > Adjust.
e Timing chain guide (top side)
Refer to the installation steps above.
ASP LCE ¢ Cylinder head cover gasket “1” [XW]
(to the cylinder head cover)
A )'S \
e Cylinder head cover “2”
f = \
0 \K a YX Cylinder head cover bolt
10 N-m (1.0 kgf-m, 7.4 lb-ft)
6 =
TIP
Ye ¢ Apply Yamaha bond No.1215 “3” onto the mat-
= XQ ing surfaces of the cylinder head cover gasket
GS Oo oo ofo ofo o OX? Ds rm and cylinder head.
Vie ‘i
* After installing the cylinder head cover gasket
“1” to the cylinder head cover, cut off the “a”
section.
¢ Make sure that the projection “b” on the cylin-
der head cover gasket is positioned on the ex-
haust side of the rib “c” on the cylinder head
cover.
10.Measure:
¢ Valve clearance
Yamaha bond No. 1215
Out of specification — Adjust.
90890-85505
Refer to “ADJUSTING THE VALVE CLEAR-
(Three bond No.1215®)
ANCE” on page 3-6.
11.Install:
%
¢ Timing mark accessing bolt “1”
S Timing mark accessing bolt

15 N-m (1.5 kgf-m, 11 Ib-ft)
|
%
¢ Crankshaft end cover “2”
S Crankshaft end cover

10 N-m (1.0 kgf-m, 7.4 Ib-ft)
|
0-30
CAMSHAFTS
A. Exhaust side
2. Install:
e Spark plug
* Ignition coil “1”
\y Spark plug
ON 13 N-m (1.3 kgf-m, 9.6 Ib-ft)
TIP
Install the ignition coils “1” in the direction shown
in the illustration.
0-31
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
OH
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
Rider seat/Passenger seat Refer to “GENERAL CHASSIS (1)” on

page 4-1.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-8.
9-32
CYLINDER HEAD
GOS

Muffler assembly Refer to “ENGINE REMOVAL’ on page 5-11.
Oil cooler inlet hose Relorto "OIL COOLER” on page 6-5.

Radiator Refer to “RADIATOR” on page 6-2.
dda pees cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS’ on page 5-20.
Clutch cover Refer to “CLUTCH” on page 5-55.

Thermostat Refer to “THERMOSTAT” on page 6-8.
1 Coolant temperature sensor coupler 1 Disconnect.
Coolant temperature sensor 1
3 Engine bracket bolt (left) 2
0-33
CYLINDER HEAD
GOH

4 Engine mounting bolt (left upper side) 1
5 Engine bracket (left) 1
6 Engine bracket bolt (right) 2
7 Engine mounting bolt (right upper side) 1
8 Engine bracket (right) 1
9 Engine mounting bolt (right front side) 1
10 Engine mounting bolt (left front side) 1
11 Timing chain bolt (right side of cylinder head) 1
12 Timing chain guide (exhaust side) 1
13 Cylinder head 1
14 Cylinder head gasket 1
15 Dowel pin 2
0-34
CYLINDER HEAD

6 Timing chain
1
1
t Timing chain guide (intake side)
0-35
CYLINDER HEAD
EASSa0276
REMOVING THE CYLINDER HEAD

1. Remove:
The following procedure applies to both of the
engine bracket.
¢ Engine bracket bolt “1”
NO
x
¢ Engine mounting bolt “2”
¢ Engine bracket “3”
TIP
e Place a suitable stand under the engine.
e Loosen the bolts in the proper sequence as
shown.
9 pee
1>€
1x©.
S XK
2. Remove:
Tt USI FAS S02 78
CHECKING THE TIMING CHAIN GUIDES

¢ Cylinder head bolt (M6) (x2) 1. Check:
¢ Cylinder head bolt (M10) (x6) ¢ Timing chain guide (exhaust side)
¢ Timing chain guide (intake side)
TIP
e Loosen the bolts in the proper sequence as
shown. EFASS02TY
e Loosen each bolt 1/2 of a turn at a time. After CHECKING THE CYLINDER HEAD
all of the bolts are fully loosened, remove them. 1. Eliminate:
¢e Combustion chamber carbon deposit
° M6 x 45 mm: “1”, “2” (with a rounded scraper)
¢ M10 x 100 mm: “3”—“8” TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
* Spark plug bore threads
¢ Valve seats
2. Check:
e Cylinder head
Damage/scratches — Replace.
e Cylinder head water jacket
Mineral deposits/rust > Eliminate.
3. Measure:
e Cylinder head warpage
Out of specification + Resurface the cylinder
head.
a Warpage limit
0.10 mm (0.0039 in)
0-36
CYLINDER HEAD
Cylinder head bolt (“1 7G”)

\y
& 1st: 10 N-m (1.0 kgf-m, 7.4 Ib-ft)

2nd: 40 N-m (4.0 kgf-m, 30 Ib-ft)
*3rd: 20 N-m (2.0 kgf-m, 15 Ib-ft)
Specified angle 90°
Cylinder head bolt (“7”, “8”)
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
“ Following the tightening order, loosen the

bolt one by one, and then retighten it to the
a. Place a straightedge “1” and a thickness specific torque.
gauge “2” across the cylinder head.
TIP
Tighten the cylinder head bolts in the tightening
sequence as shown and torque them in 4 stag-
es.
x2
b. Measure the warpage. x6 FWD
c. If the limit is exceeded, resurface the cylin- “e
der head as follows.
d. Place a 400-600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
EASa0282
INSTALLING THE CYLINDER HEAD

1. Install:
¢ Cylinder head
¢ Cylinder head bolt (M10) (x6) XE
¢ Cylinder head bolt (M6) (x2)
TIP
e Pass the timing chain through the timing chain
cavity.
e Lubricate the cylinder head bolt (M10) threads
and mating surface with engine oil.
2. Tighten:
¢ Cylinder head bolt “1”—“6”
e Cylinder head bolt “7”, “8”
0-37
VALVES AND VALVE SPRINGS
EASZO045

Removing the valves and valve springs

Cylinder head Refer to “CYLINDER HEAD” on page 5-32.
Valve lifter
Valve pad
ho]
Valve cotter 16
]
Valve spring retainer

om) &/
Valve spring
&!
@)
&|
Exhaust valve
oO); S|)
Intake valve
S|;
co) ©;
Valve stem seal

Valve spring seat
;
oO)
Valve guide
=k
©
0-38
EASa0283
TIP
REMOVING THE VALVES
The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
TIP —"
Before removing the internal parts of the cylinder

head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove:
Valve spring compressor
© Valve lifter “1” YM-04019
¢ Valve pad “2” Valve spring compressor attach-
TIP ment (026)
Make a note of the position of each valve lifter 90890-01243
and valve pad so that they can be reinstalled in Valve spring compressor adapter
their original place. (26 mm)
YM-01253-1
2. Check:
¢ Valve sealing 4. Remove:
Leakage at the valve seat > Check the valve e Valve spring retainer “1”
face, valve seat, and valve seat width. e Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” e Valve “3”
on page 5-41. e Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and ¢ Valve spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
FASS0264
CHECKING THE VALVES AND VALVE

3. Remove:
GUIDES
e Valve cotter
The following procedure applies to all of the
valves and valve guides.
1. Measure:
0-39
¢ Valve-stem-to-valve-guide clearance
Out of specification — Replace the valve
guide.
e Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
a Valve-stem-to-valve-guide clear- — .
ane a eeoae mm (0.0004—-0.0015 b. Install the new valve guide with the valve
in) guide installer “2” and valve guide remover
Limit oT.
0.080 mm (0.0032 in) —
Valve-stem-to-valve-guide clear- Valve guide position
ance (exhaust) 14.8-1 5.2 mm (0.58—0.60 in)
0.025—0.052 mm (0.0010-—0.0020
in) ® 2
Limit
0.100 mm (0.0039 in)
Co)
a. Valve guide position
c. After installing the valve guide, bore the
valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valve-
guide clearance.
2. Replace:
¢ Valve guide
vip TIP
To ease valve guide removal and installation, ae repracing the valve guide, reface the valve
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
a. Remove the valve guide with the valve

guide remover “1”.
9-40
e Valve seat
Valve guide remover (@4.5) Pitting/wear —> Replace the cylinder head.
90890-04116 3. Measure:
Valve guide remover (4.5 mm) e Valve seat width “a”
YM-04116 Out of specification + Replace the cylinder
Valve guide installer (04.5) head.
90890-04117
Valve guide installer (4.5 mm) Valve seat contact width (intake)
YM-04117 0.90-—1.10 mm (0.0354—0.0433
Valve guide reamer (94.5) in)
90890-04118 Limit
Valve guide reamer (4.5 mm) 1.6 mm (0.06 in)
YM-04118 Valve seat contact width (ex-
haust)
3. Eliminate: 0.90—1.10 mm (0.0354—0.0433
¢ Carbon deposit in)
(from the valve face and valve seat) Limit
4. Check: 1.6 mm (0.06 in)
* Valve face
Pitting/wear —> Grind the valve face.
¢ Valve stem end
Mushroom shape or diameter larger than the A\
body of the valve stem — Replace the valve. \

5. Measure:
Pf?
¢ Valve stem runout
Out of specification — Replace the valve.
TIP
¢ When installing a new valve, always replace
the valve guide. a. Apply blue layout fluid “b” onto the valve
¢ If the valve is removed or replaced, always reface.
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
foagl b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
I _ sion.
PLAS PSLALAL
SSE SLEEP APSA SG SS
d. Measure the valve seat width.
EASa0285
TIP
CHECKING THE VALVE SEATS Where the valve seat and valve face contacted
The following procedure applies to all of the one another, the blueing will have been re-
valves and valve seats. moved.
1. Eliminate:
¢ Carbon deposit 4. Lap:
(from the valve face and valve seat) e Valve face
2. Check: e Valve seat
5-41
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
a. Apply a coarse lapping compound “a” to the

valve face. b
ECAIS3790
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve h. Install the valve into the cylinder head.
guide. i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If
the valve seat width is out of specification,
reface and lap the valve seat.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound. CHECKING THE VALVE SPRINGS
TIP The following procedure applies to all of the
For the best lapping results, lightly tap the valve valve springs.
seat while rotating the valve back and forth be- 1. Measure:
tween your hands. ¢ Valve spring free length “a”
Out of specification — Replace the valve
spring.
Free length (intake)

40.30 mm (1.59 in)
Limit
38.29 mm (1.51 in)
Free length (exhaust)
41.39 mm (1.63 in)
Limit
e. Apply a fine lapping compound to the valve 39.32 mm (1.55 in)
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve
face.
9-42
Ss
2. Measure:
—_——_
* Valve spring tilt “a”

a
2. Lubricate:
(}
e Valve stem “1”
Out of specification —+ Replace the valve e Valve stem end
spring. (with the recommended lubricant)
Spring tilt (intake) Recommended lubricant

1.8 mm (0.07 in) Molybdenum disulfide oil
Spring tilt (exhaust)
1.8 mm (0.07 in) 3. Lubricate:
e Valve stem seal “2”
(with the recommended lubricant)
<a
= Recommended
Silicone fluid
lubricant
MOO
CHECKING THE VALVE LIFTERS
valve lifters.
1. Check:
4. Install:
° Valve lifter
Damage/scratches — Replace the valve lift- e Valve spring seat “1”
ers and cylinder head. (into the cylinder head)
e Valve stem seal “2” [XEN
EAS30288
e Valve “3”
INSTALLING THE VALVES
e Valve spring “4”
¢ Valve spring retainer “5”
valves and related components.
1. Deburr: TIP
e Valve stem end ¢ Make sure each valve is installed in its original
(with an oil stone) place.
* Install the valve springs with the larger pitch “a”
facing up.
9-43
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
Nifty,
preste
.! [w=
Qo
—
|
Loy fo
—=y
C)
7. Lubricate:
e Valve lifter
=| Recommended lubricant
; .
b. Smaller pitch Engine oil
5. Install: 8. Install:
¢ Valve cotter e Valve pad
TIP e Valve lifter
Install the valve cotters by compressing the TIP
valve spring with the valve spring compressor ¢ The valve lifter must move smoothly when ro-
“1” and the valve spring compressor attachment tated with a finger.
“2. ¢ Each valve lifter and valve pad must be rein-
stalled in their original position.
90890-04019
YM-04019
Valve spring compressor attach-
ment (926)
90890-01243
Valve spring compressor adapter
(26 mm)
YM-01253-1
6. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
9-44
GENERATOR AND STARTER CLUTCH
EAS20140

Removing the stator coil, generator rotor and starter clutch
GOH

Rider seat/Passenger seat page 4-1.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-96.
Coolant reservoir Refer to “RADIATOR” on page 6-2.
Drain.
page 3-22.
1 Stator coil coupler 1 Disconnect.
9-45
GOH
Job/Parts to remove
2 Crankshaft position sensor coupler 1 Disconnect.
3 Crankshaft end cover 1
4 Timing mark accessing bolt 1
5 Oil filler cap 1
6 Generator cover 1
7 Generator cover gasket 1
8 Bearing 1
9 Dowel pin 2
10 Stator coil lead holder 1
14 Stator coil assembly (Stator coil/Crankshaft {
position sensor)
12 Torque limiter 1
0-46
GOH

13 Bearing 1
14 Generator rotor 1
15 Starter clutch 1
16 Woodruff key 1
17 Starter clutch idle gear shaft 1
18 Starter clutch idle gear 1
19 Starter clutch gear 1
9-47
EASS0R87
REMOVING THE GENERATOR

1. Remove:
e Generator rotor bolt “1”
« Washer
TIP
While holding the generator rotor “2” with the ro-
tor holding tool “3S”, loosen the generator rotor
bolt.
Rotor holding tool EAS S086

90890-04166 ee THE STARTER CLUTCH
Rotor holding tool
undies °° e Starter clutch bolt “1”
e Starter clutch
TIP
While holding the generator rotor “2” with the ro-
tor holding tool “S”, loosen the starter clutch
bolts.
Rotor holding tool

90890-04166
Rotor holding tool
YM-04166
2. Remove:
¢ Generator rotor “1”
(with the flywheel puller “2”)
¢ Woodruff key
ECA13880
NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.
TIP EAsooees
¢ Install the flywheel puller bolts to the threaded CHECKING THE STARTER CLUTCH
holes of the starter clutch. 1. Check:
¢ Make sure the flywheel puller is centered over ¢ Starter clutch roller
the generator rotor. Damage/wear — Replace.
2. Check:
e Starter clutch idle gear
Flywheel puller e Starter clutch gear
90890-01362 Burrs/chips/roughness/wear — Replace the
Heavy duty puller defective part(s).
YU-33270-B 3 Check:
e Starter clutch gear contact surface
Damage/pitting/wear > Replace the starter
clutch gear.
4. Check:
e Starter clutch operation
0-48
a. Install the starter clutch gear “1” onto the

generator rotor “2” and hold the generator
rotor.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be re-
placed.
c. When turning the starter clutch gear coun-
terclockwise “B”, it should tur freely, other-
wise the starter clutch is faulty and must be
replaced.
FASS08T2
INSTALLING THE GENERATOR

1. Install:
EASSa0870 ¢ Woodruff key
CHECKING THE TORQUE LIMITER ¢ Generator rotor
1. Check:
e Washer XRT
¢ Torque limiter
e Generator rotor bolt
Damage/wear — Replace.
TIP
TIP
¢ Clean the tapered portion of the crankshaft and
Do not disassemble the torque limiter.
the generator rotor hub.
¢ When installing the generator rotor, make sure
EASSOaT1
INSTALLING THE STARTER CLUTCH the woodruff key is properly seated in the key-
1. Install: way of the crankshaft.
e Starter clutch “1”
* Lubricate the generator rotor bolt threads and
X
washer mating surfaces with engine oil.
\ Starter clutch bolt
32 N-m (3.2 kgf-m, 24 Ib-ft)
2. Tighten:
e Generator rotor bolt “1”
LOCTITE®
XY Generator rotor bolt

TIP
e Install the starter clutch so that the side of the Ry 70 N-m (7.0 kgf-m, 52 Ib-ft)
starter clutch roller assembly with the arrow TIP

mark “a” is toward the generator rotor “2”. While holding the generator rotor “2” with the ro-
¢ While holding the generator rotor with the rotor tor holding tool “3”, tighten the generator rotor
holding tool “3”, tighten the starter clutch bolts bolt.
“a
Rotor holding tool

Rotor holding tool 90890-04166
90890-04166 Rotor holding tool
Rotor holding tool YM-04166
YM-04166
9-49
3. Install: 6. Install:
* Bearing “1” ¢ Generator cover gasket JEW]
TIP ¢ Generator cover
Make sure that the bearing does not protrude
past the surface “a” of the cylinder. Generator cover bolt
12 N-m (1.2 kgf-m, 8.9 lb-ft)
LOCTITE®
Generator cover bolt
12 N-m (1.2 kgf-m, 8.9 lb-ft)
TIP
* Tighten the generator cover bolts in stages and
in a crisscross pattern.
¢ Apply LOCTITE® to the threads of only the
generator cover bolts “1” shown in the illustra-
tion.
4. Apply:
¢ Sealant
(onto the stator coil lead grommet)
Yamaha bond No. 1215

90890-85505
7. Connect:
e Stator coil coupler
¢ Crankshaft position sensor coupler
TIP
To route the stator coil lead, refer to “CABLE
ROUTING” on page 2-15.
5. Install:
* Bearing “1”
TIP
Make sure that the bearing contacts the surface
“a’ of the generator cover “2”.
9-50
ELECTRIC STARTER
EAS2O052
ELECTRIC STARTER
Removing the starter motor
Rider seat/Passenger seat ee CHASSIS (1)” on

Pivot shaft protectors Refer to “SWINGARM’” on page 4-90.
Throttle bodies/Ajir filter case Refer to “THROTTLE BODIES” on page 7-8.
Canister Rafer to"PUEL TANK” on page 7-1

1 Gear position switch coupler 1
2 Coupler and hose bracket 1
3 Starter motor lead 1 Disconnect.
4 Starter motor 1
5 Canister holder 1 For California only.
9-51
ELECTRIC STARTER
Disassembling the starter motor

O-ring
Starter motor front cover
Po
Starter motor yoke

cw!
Armature assembly
om] &/
Gasket
om)
Brush holder set

~s|
Starter motor rear cover

oo);
Lead guide
9-52
ELECTRIC STARTER
EASa0g25
CHECKING THE STARTER MOTOR

1. Check:
¢ Commutator
Dirt + Clean with 600 grit sandpaper.
2. Measure:
¢ Mica undercut “a”
Out of specification — Cut the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth) 4. Measure: .

0.70 mm (0.03 in) ¢ Brush length “a
Out of specification - Replace the brush
TIP holder set.
The mica of the commutator must be undercutto —
ensure proper operation of the commutator. Brush overall length limit
6.5 mm (0.26 in)
Ti?
3. Measure:
e Armature assembly resistance o. Measure:
Out of specification — Replace the starter ¢ Brush spring force
motor. Out of specification —+ Replace the brush
a. Measure the armature assembly resistance holder set.
with the digital circuit tester.
Brush spring force
6.03-6.52 N (615-665 of, 21.71-
Digital circuit tester (CD732)
23.47 oz)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
= Armature coil resistance

0.016—0.024 ©
b. If the resistance is out of specification, re-

place the starter motor.
6. Check:
e Gear teeth
Damage/wear — Replace the starter motor.
7. Check:
¢ Bearing
e Oil seal
9-93
ELECTRIC STARTER
Damage/wear — Replace the starter motor

front cover.
EASS0326
ASSEMBLING THE STARTER MOTOR

1. Install:
* Lead guide “1”
TIP
Make sure that the slot “a” in the lead guide is
facing in the direction shown in the illustration.
2. Install:
¢ Coupler and hose bracket “1”
TIP
Make sure that the tab “a” on the coupler and
hose holder bracket contacts the projection “b”
on the cylinder block.
2. Install:
e Starter motor yoke “1”
¢ Starter motor front cover “2”
e Starter motor rear cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front cover
and rear covers.
:7
ll
\
EASs0327
INSTALLING THE STARTER MOTOR

1. Install:
¢ Canister holder “1”(for California only)
¢ Starter motor “2”
¢ Canister “3”(for California only)
TIP
e Pass the starter motor front cover bolts through
the slots “a” in the canister holder to secure it.
e Install the canister holder with the stamped
mark “2RC” “b” facing forward.
0-54
CLUTCH
EAS20055
CLUTCH
Removing the clutch cover and pull lever shaft
GH

Drain.
page 3-22.
Water pump housing Refer to “WATER PUMP” on page 6-10.
1 Clutch cable 1 Disconnect.
2 Clutch cable holder 1
3 Holder (O. sensor lead and oil pressure switch 9
lead)
Clutch cover 1
5 Clutch cover gasket 1
9-99
CLUTCH
Removing the clutch cover and pull lever shaft
BH

6 Dowel pin 2
7 Circlip 1
8 Pull lever 1
9 Pull lever spring 1
10 Circlip 1
11 Pull lever shaft 1
12 Oil seal 1
13 Bearing 1
14 Bearing 1
0-56
CLUTCH
Removing the clutch
GOH

Compression spring
a
Pressure plate
Po
Pull rod
G]
Bearing
&/]
Friction plate 1 Inside diameter: 120 mm (4.72 in)

|) m1)
ee
Clutch plate
ee
SN)
Friction plate 2 Inside diameter: 119 mm (4.69 in)

co;
ee
Clutch boss nut

Conical spring washer
(o/;
Washer
—h
©
Clutch boss
—
—_—
9-57
CLUTCH
Removing the clutch
GOH

12 Thrust plate 1
13 Spacer 1
14 Bearing 1
15 Clutch housing 1
16 Thrust plate 1
17 Oil pump drive chain 1
18 Oil pump drive chain guide 1
0-58
CLUTCH
RewOrni THE CLIC : Glutch boss nut “1”

aie 5. Loosen:
¢ Clutch cover “1” TIP.

* Gasket While holding the clutch boss “2” with the univer-
Tip sal clutch holder “3”, loosen the clutch boss nut.
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the Universal clutch holder
bolts are fully loosened, remove them. 90890-04086
Universal clutch holder
YM-91042
2. Remove:
¢ Compression spring bolt “1”
¢ Compression spring
¢ Pressure plate “2” e Spacer “4 ”
¢ Pull rod “3” e Bearing “2”
TIP e Clutch housing “3”
Loosen the compression spring bolts in stages a. Remove the spacer and bearing.
and in a crisscross pattern.
b. Remove the oil pump drive chain “4” from

the oil pump driven sprocket “a”, and then
remove the clutch housing.
* Friction plate 1
¢ Clutch plate
* Friction plate 2
4. Straighten the clutch boss nut rib “a”.
9-59
CLUTCH
CHECKING THE FRICTION PLATES oe — Replace the clutch plates as a

bi a procedure applies to all of the fric- > Weasure:
1. Check: ¢ Clutch plate warpage

(with a surface plate and thickness gauge “1”)
* Friction plate
Out of specification + Replace the clutch
Damage/wear — Replace the friction plates
plates as a set.
as a set.
2. Measure:
¢ Friction plate thickness “Soaenaatee
Out of specification — Replace the friction Feeler gauge set
plates as a set. YU-26900-9
TIP
Measure the friction plate at four places.
Friction plate 1 thickness

2.90—3.10 mm (0.114—0.122 in)
Wear limit
2.82 mm (0.111 in)
Friction plate 2 thickness
2.92—3.08 mm (0.115—0.121 in)
Wear limit
2.80 mm (0.110 in)
FASS0351
CHECKING THE CLUTCH SPRINGS

clutch springs.
1. Check:
e Clutch spring
Damage — Replace the clutch springs as a
set.
2. Measure:
¢ Clutch spring free length “a”
Out of specification — Replace the clutch
springs as a Set.
Clutch spring free length

50.00 mm (1.97 in)
Limit
47.50 mm (1.87 in)
A. Friction plate 1
B. Friction plate 2
EASS0349
CHECKING THE CLUTCH PLATES

clutch plates.
1. Check:
* Clutch plate
0-60
CLUTCH
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
FASS0S54
CHECKING THE PRESSURE PLATE

1. Check:
e Pressure plate “1”
Cracks/damage —> Replace.
¢ Bearing “2”
EAS30352
CHECKING THE CLUTCH HOUSING
1. Check:
¢ Clutch housing dog
Damage/pitting/wear — Deburr the clutch
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
| EFAS 30356
| CHECKING THE PRIMARY DRIVE GEAR

1. Check:
e Primary drive gear
Damage/wear — Replace the crankshaft and
clutch housing as a set.
Excessive noise during operation — Replace
the crankshaft and clutch housing as a set.
EASS0357
2. Check: CHECKING THE PRIMARY DRIVEN GEAR

¢ Oil pump drive sprocket “1” 1. Check:
Cracks/damage/wear — Replace. e Primary driven gear “1”
Damage/wear — Replace the clutch housing
and crankshaft as a set.
Excessive noise during operation > Replace
the clutch housing and crankshaft as a set.
3. Check:
* Bearing
Damage/wear — Replace the bearing and
clutch housing.
EASa0g53
CHECKING THE CLUTCH BOSS

1. Check:
¢ Clutch boss spline
Damage/pitting/wear — Replace the clutch
boss.
0-61
CLUTCH
EASa0358
TIP
CHECKING THE PULL LEVER SHAFT AND
PULL ROD ¢ Lubricate the conical spring washer and clutch
1. Check: boss nut threads with engine oil.
¢ Pull lever shaft pinion gear teeth “1” ¢ Install the washer on the main axle with the
¢ Pull rod teeth “2” “OUT” mark facing away from the vehicle.
Damage/wear — Replace the pull rod and ¢ While holding the clutch boss “1” with the uni-
pull lever shaft as a set. versal clutch holder “S”, tighten the clutch boss
nut.
¢ Stake the clutch boss nut at a cutout “a” in the
main axle.

90890-04086
YM-91042
2. Check:
¢ Pull rod bearing
EASSa0383
INSTALLING THE CLUTCH

1. Install:
¢ Oil pump drive chain “1”
¢ Thrust plate
¢ Clutch housing “2”
* Bearing
¢ Spacer
TIP
Install the oil pump drive chain onto the oil pump
drive sprocket “a”.
:
5
3. Install:
e Friction plate 1 “1”
D
PPT LL
¢ Friction plate 2 “2”

TIP
gf
Q_
=
* First, install a friction plate, and then alternate

between a clutch plate and a friction plate.
2. Install:
¢ Align a projection on friction plate 1 with the
¢ Thrust plate
punch mark “a” on the clutch housing and align
¢ Clutch boss “1”
a projection on friction plate 2 with the “,,”
e Washer
mark “b” on the housing.
* Conical spring washer
¢ Clutch boss nut “2” [XW
Clutch boss nut

% 95 N-m (9.5 kgf-m, 70 Ib-ft)
9-62
CLUTCH
4. Install:
* Bearing
¢ Pull rod “1”
¢ Pressure plate “2”
¢ Clutch spring
¢ Clutch spring bolt “3”
\y Clutch spring bolt

g 8 N-m (0.8 kgf-m, 5.9 Ib-ft)
TIP
e Apply lithium-soap-based grease onto the pull 6. Install:
rod. e Pull lever
e Tighten the clutch spring bolts in stages and in TIP
a crisscross pattern. ¢ Install the pull lever with the “UP” mark “a” fac-
ing toward upper side.
« ¢ When installing the pull lever, push the pull le-
ver and check that the punch mark “b” on the
pull lever aligns with the mark “c” on the clutch
cover.
"|
Ys. \ 2
5. Install:
* Bearing “1”
* Oil seal “2” [TEM
(to the clutch cover)
TIP
¢ Lubricate the bearings with engine oil and lubri-
cate the oil seal with lithium-soap-based
grease.
e Install the bearings until they contact the sur-
faces “a” and install the oil seal until it contacts
the surface “b” as shown in the illustration.
0-63
CLUTCH
7. Install: TIP
¢ Dowel pin “1” ¢ Install the clutch cable so that the clutch cable
* Clutch cover gasket “2” [Rta length “a” is 51.6-62.2mm (2.03-2.45 in) as
¢ Clutch cover “3” shown in the illustration. In addition, make sure
¢ Clutch cable holder “4” that the vehicle is positioned upright when
measuring the clutch cable length.
\y Clutch cover bolt ¢ After installing the clutch cable, bend the pro-
| 12 N-m (1.2 kgf-m, 8.9 Ib-ft) jection “b” on the pull lever.
Clutch cable holder bolt
12 N-m (1.2 kgf-m, 8.9 Ib-ft)
LOCTITE®
TIP
e Align the slit “a” in the impeller shaft with the
projection “b” on the oil pump driven sprocket.
¢ Face the serrations on the clutch pull rod “5”
rearward and align the rod with the hole “c” in
the clutch cover.
e Make sure that the pull rod teeth and pull lever
shaft pinion gear are engaged.
e Apply locking agent (LOCTITE®) to the
threads of only the clutch cable holder bolts “6”
shown in the illustration.
e Tighten the bolts in stages and in a crisscross
pattern.
YN y/ Wo oN
3 iA 9. Adjust:
3} Se \\ oa e Clutch lever free play
Refer to “ADJUSTING THE CLUTCHLEVER
f 59S
ea i s
FREE PLAY” on page 3-12.
\= Clutch lever free play

XN [VANE 5.0—10.0 mm (0.20-—0.39 in)
Se)
8. Connect:
¢ Clutch cable “1”
0-64
SHIFT SHAFT
EASZO057
SHIFT SHAFT
Removing the shift shaft and stopper lever
GOS

Clutch housing Refer to “CLUTCH” on page 5-55.
Circlip
lh
ho]
Washer
ee
Shift shaft
]
om) &/
Washer
Circlip
@)
Washer
ffm
oO); S|)
Stopper lever
Stopper lever spring
fm
Collar
;
mm
0-65
SHIFT SHAFT
Removing the shift shaft and stopper lever
GOH
Order Job/Parts to remove

10 Shift shaft spring
11 Shift shaft spring stopper
12 Oil seal
13 Bearing
0-66
SHIFT SHAFT
EASaoa7?
CHECKING THE SHIFT SHAFT Derg2). - 1

1. Check: iS ——_
© Shift shaft “1”
Bends/damage/wear — Replace.
¢ Shift shaft spring “2”
¢ Collar
2. Install:
e Shift shaft spring stopper
e Washer
e Shift shaft assembly
e Stopper lever spring
shift shaft spring stopper
EASSa0378
& 22 N-m (2.2 kgf-m, 16 Ib-ft)
LOCTITE®
CHECKING THE STOPPER LEVER
1. Check: TIP
e Stopper lever “1” * Hook the end of the shift shaft spring “2” onto
Bends/damage — Replace. the shift shaft spring stopper “1”.
Roller turns roughly > Replace the stopper ¢ Hook the ends of the stopper lever spring “3”
lever. onto the stopper lever “4” and the stopper lever
spring hook “5”.
¢ Mesh the stopper lever with the shift drum seg-
ment assembly.
Why 40
Es«S30381
INSTALLING THE SHIFT SHAFT

1. Install:
* Bearing “1” J O N =)
° Oil seal “2” NENG

Install depth “a”
0.6—1.1 mm (0.02—0.04 in)
TIP
e Apply engine oil onto the bearing.
e Make sure that the bearing does not protrude
past the line “b” shown in the illustration.
e Lubricate the oil seal lips with lithium-soap-
based grease.
0-67
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump
GOS ly

1 Oil pump assembly 1
2 Holder 1
0-68
OIL PUMP
Disassembling the oil pump

Oil pump cover
Oil pump rotor assembly
Ph
Oil pump inner rotor

|
Oil pump outer rotor

&!
Mm) oy)
Pin
Oil pump driven sprocket
Hold down the washer when removing the
Circlip circlip.
~!
Washer
Oo; ©
Spring
Relief valve
11 Dowel pin
0-69
OIL PUMP
EASa0396
CHECKING THE SPROCKET AND CHAIN

1. Check:
¢ Oil pump drive sprocket
Refer to “CHECKING THE CLUTCH HOUS-
ING” on page 5-61.
¢ Oil pump driven sprocket
Refer to “CHECKING THE OIL PUMP” on
page 5-70.
2. Check:
¢ Oil pump drive chain
1. Inner rotor
Damage/stiffness — Replace the oil pump
2. Outer rotor
drive chain, oil pump drive sprocket (clutch
housing), and oil pump driven sprocket as a 3. Check:
set. ¢ Oil pump operation
Rough movement — Repeat steps (1) and
EASsa0aa7
CHECKING THE OIL PUMP (2) or replace the defective part(s).

1. Check:
¢ Oil pump driven sprocket “1”
¢ Oil pump housing “2”
Cracks/damage/wear — Replace the defec-
tive part(s).
EAS 30338
CHECKING THE RELIEF VALVE

1. Check:
¢ Relief valve “1”
¢ Spring “2”
2. Measure: Damage/wear —> Replace the oil pump as-
* Inner-rotor-to-outer-rotor-tip clearance “a” sembly.
¢ Outer-rotor-to-oil-pump-housing clearance
“hy”
Inner-rotor-to-outer-rotor-tip
clearance
0.03—0.08 mm (0.0012—0.0032
in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance EASS0342
0.09—0.15 mm (0.0035—0.0059 ASSEMBLING THE OIL PUMP
in) 1. Lubricate:
Limit e Inner rotor
0.22 mm (0.0087 in) e Outer rotor
= Recommended
Engine oil
lubricant
2-70
OIL PUMP
2. Lubricate: ECA20940
* Oil pump driven sprocket NOTICE
(with the recommended lubricant) After installing the oil pump drive chain and
driven sprocket, make sure the oil pump
,| Recommended lubricant turns smoothly.
Engine oil
3. Install:
¢ Oil pump driven sprocket “1”
¢ Pin “2”
e Outer rotor “3”
e Inner rotor “4”
¢ Oil pump cover “5”
e Oil pump cover screw “6”
Oil pump cover screw

ZN 3.8 N-m (0.38 kgf-m, 2.8 Ib-ft)
TIP
Align the pin in the oil pump shaft with the
grooves “a” in the inner rotor.
4. Check:
¢ Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-70.
EASa0343
INSTALLING THE OIL PUMP

1. Install:
¢ Oil pump “1”
¢ Oil pump bolt “2”
Oil pump bolt

ZN 12 N-m (1.2 kgf-m, 8.9 Ib-ft)
5-71
OIL PAN
EaAs2o1 77
OIL PAN
Removing the oil pan
a, >
(11)
Pivot shaft protector (right) Refer to “SWINGARM” on page 4-90.
Muffler assembly Refer to “ENGINE REMOVAL’ on page 5-11.
Drain.
page 3-22.
1 Engine oil drain bolt 1
2 Oil pan 1
3 Oil pan gasket 1
4 Oil strainer 1
9-72
OIL PAN
EAS31 068
REMOVING THE OIL PAN

1. Remove:
¢ Oil pan “1”
¢ Oil pan gasket
TIP
e Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
e Insert a flat-head screwdriver into the slots “a”
in the oil pan to remove the oil pan.
E4531 089
CHECKING THE OIL STRAINER

1. Check:
e Oil strainer
Damage — Replace.
Contaminants — Clean with solvent.
EAS31070
INSTALLING THE OIL PAN

1. Install:
* Oil pan gasket [XANF
¢ Oil pan
Ay Oil pan bolt

ZN 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
2. Install:
¢ Gasket JEW
¢ Engine oil drain bolt
Engine oil drain bolt

% 43 N-m (4.3 kgf-m, 32 Ib-ft)
0-73
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase
Engine Refer to “ENGINE REMOVAL’ on page 5-11.
Cylinder head cover Refer to “CAMSHAFTS” on page 5-20.
Cylinder head Refer to “CYLINDER HEAD” on page 5-32.
Starter clutch
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-45.
Starter motor
Refer to “ELECTRIC STARTER’ on page 5-
51.
Oil strainer Refer to “OIL PAN” on page 5-72.
9-74
CRANKCASE
Separating the crankcase
Q\
Mm __)
*

Oil cooler Refer to “OIL COOLER’ on page 6-5.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-96.
Oil pressure switch
—
Cylinder plug
ho!)
Gear position switch

w)
&)
Balancer shaft access cover

meee
1)
Main gallery bolt

am)
Crankcase
Dowel pin
CO) S|)
Blind plate
9-75
CRANKCASE
EASa0389
DISASSEMBLING THE CRANKCASE NOTICE

1. Place the engine upside down. Tap on one side of the crankcase with a soft-
2. Remove: face hammer. Tap only on reinforced por-
¢ Crankcase bolt (x27) tions of the crankcase, not on the crankcase
TIP mating surfaces. Work slowly and carefully
e Loosen each bolt 1/4 of a turn at a time, in stag- and make sure the crankcase halves sepa-
es and in a crisscross pattern. After all of the rate evenly.
bolts are fully loosened, remove them.
e Loosen the bolts “1”—“11” in any loosening se- EAS 30390
quence. CHECKING THE CRANKCASE

e Loosen the bolts “12”—"27” in the proper se- 1. Thoroughly wash the crankcase halves in a
quence as shown. mild solvent.
e The numbers embossed “1”—“16” on the crank- 2. Thoroughly clean all the gasket surfaces and
case indicate the crankcase tightening se- crankcase mating surfaces.
quence. 3. Check:
e Crankcase
¢ M6 x 40 mm bolt (x8): “1”, “2”, “4”—"7", “10”, Cracks/damage —> Replace.
a 5 hi
e Oil delivery passage

¢ M6 x 60 mm bolt (x3): “3”, “8”, “9” Obstruction > Blow out with compressed air.
¢ M6 x 65 mm bolt (x2): “12”, “13”
¢ M8 x 65 mm bolt (x2): “14”, “15” EAS S0397
ASSEMBLING THE CRANKCASE

¢ M8 x 70 mm bolt (x6) (bolts with O-rings):
1. Lubricate:
“16"— “21”
¢ Crankshaft journal bearing inner surface
¢ M9 x 80 mm bolt (x6) (bolts with washers):
“22 — 27”
i
x8
7
2. Apply:
Recommended
Engine oil
lubricant
¢ Sealant
6
(onto the crankcase mating surfaces)
f- Yamaha bond No. 1215

90890-85505
ECA0B80
NOTICE
Do not allow any sealant to come into con-
tact with the oil gallery, crankshaft journal
bearings, or balancer shaft journal bearings.
3. Remove:
e Crankcase
* Dowel pin
0-76
CRANKCASE
TIP
* Tighten the bolts “1°—“16” in the order of the
O )
embossed numbers on the crankcase.
¢ Lubricate the bolts “1”—“6” threads, mating sur-
ao)
Pil
faces and washers with engine oll.
iy
¢ Lubricate the bolts “7”—“12” threads, mating
FY “(eo
surfaces and O-rings with engine oil.
( © ¢ Lubricate the bolts “13”—“27” threads and mat-

ing surfaces with engine oil.
( O
¢ M9 x 80 mm bolt (x6) (bolts with washers):
“4’—6" TE
¢ M8 x 70 mm bolt (x6) (bolts with new O-
rings): “7°—"12”
¢ M8 x 65 mm bolt (x2): “13”, “14”
Act 4 ¢ M6 x 65 mm bolt (x2): “15”, “16”
¢ M6 x 40 mm bolt (x8): “17”, “18”, “21"—"24”,
"26", “27”
¢ M6 x 60 mm bolt (x3): “19”, “20”, “25”
O an" 7 i
<>
= : O
* Dowel pin
4. Setthe shift drum assembly and transmission
gears in the neutral position.
5. Install:
¢ Crankcase “1”
(onto the cylinder “2”)
ECA13980
NOTICE
Before tightening the crankcase bolts, make
sure the transmission gears shift correctly
when the shift drum assembly is turned by
hand.
7. Tighten:
e Crankcase bolt “1”—“6”
Crankcase bolts (bolts with

6. Install: washers) “1”—“6”
¢ Crankcase bolt (x27) 1st: 24 N-m (2.4 kgf-m, 18 Ib-ft)
*2nd: 17 N-m (1.7 kgf-m, 13 Ib-ft)
Final: specified angle 60°
* Following the tightening order, loosen the

bolt one by one, and then retighten it to the
specific torque.
CRANKCASE
EWAI6610
If the bolt is tightened more than the speci-

fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
TIP
Tighten the bolts in the tightening sequence cast
on the crankcase.
EASS1071
INSTALLING THE OIL PRESSURE SWITCH

1. Install:
e Oil pressure switch “1”
¢ Oil pressure switch lead “2”
Y Oil pressure switch

x 15 N-m (1.5 kgf-m, 11 Ib-ft)
Oil pressure switch lead bolt
1.8 N-m (0.18 kgf-m, 1.3 lb-ft)
2. Apply:
e Sealant
(onto the oil pressure switch threads)
8. Tighten: Yamaha bond No. 1215

¢ Crankcase bolt “7”—“27” 90890-85505
| Crankcase bolts “7”-—"14”
zy 24 N-m (2.4 kgf-m, 18 Ib-ft) TIP
Crankcase bolts “15”—"27” ¢ Apply Three bond No.1215® to the threads “a”
10 N-m (1.0 kgf-m, 7.4 Ib-ft) of the oil pressure switch. However, do not ap-
ply Three bond No.1215® to the portion “b” of
TIP the oil pressure switch.
¢ Tighten the bolts “7"—"16" in the tightening se- ¢ Install the oil pressure switch lead so that it is
quence cast on the crankcase. routed within the range shown in the illustra-
e Tighten the bolts “17”—“27” in any tightening tion.
sequence using a crisscross pattern.
0-78
CRANKCASE
0-79
CONNECTING RODS AND PISTONS
EaAS201 a2

Removing the connecting rods and pistons

connecting rods and pistons.
Refer to “CRANKCASE” on page 5-74.
Connecting rod cap
of; &/ co] fo) —
Big end lower bearing

et
Big end upper bearing

Piston pin clip
Piston pin
meme
“} &)}
Piston
Connecting rod
mf
0-80
Removing the connecting rods and pistons

8 Top ring 1
9 2nd ring 1
10 Oil ring 1
0-81
EASSa0T45
REMOVING THE CONNECTING RODS AND

PISTONS
The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:
¢ Connecting rod cap “1”
¢ Connecting rod
* Big end bearing
TIP
¢ Identify the position of each connecting rod cap
so that it can be reinstalled in its original place.
e After removing the connecting rods and con-
necting rod caps, care should be taken not to
damage the mating surfaces of the connecting
ee
rods and connecting rod caps.
———
3. Remove:
e Top ring
e 2nd ring
e Oil ring
TIP
When removing a piston ring, open the end gap
2. Remove: with your fingers and lift the other side of the ring
¢ Piston pin clip “1” over the piston crown.
¢ Piston pin “2”
¢ Piston “3”
¢« Connecting rod “4”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
e For reference during installation, put identifica-
tion marks on the piston crown.
e Before removing the piston pin, deburr the pis- FASSOT4T
ton pin clip groove and the piston pin bore ar- CHECKING THE CYLINDER AND PISTON
ea. If both areas are debarred and the piston The following procedure applies to all of the cyl-
pin is still difficult to remove, remove it with the inders and pistons.
piston pin puller set “5”. 1. Check:
e Piston wall
&
e Cylinder wall
Piston pin puller set Vertical scratches — Replace the cylinder,
90890-01304
and replace the piston and piston rings as a
Piston pin puller
set.
YU-01304
2. Measure:
e Piston-to-cylinder clearance
a. Measure cylinder bore with the cylinder
bore gauge.
9-82
TIP f. If out of specification, replace the cylinder,

Measure cylinder bore by taking side-to-side and replace the piston and piston rings asa
and front-to-back measurements of the cylinder. set.
FAS S0748
CHECKING THE PISTON RINGS

Bore
1. Measure:
80.000-80.010 mm (3.1496- e Piston ring side clearance
3.1500 in)
Wear limit
Out of specification + Replace the piston
80.060 mm (3.1520 in) and piston rings as a set.
TIP
Cylinder bore = maximum of D, —D, Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Top ring
Ring side clearance
0.030—0.065 mm (0.0012—0.0026
in)
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
b. If out of specification, replace the cylinder, 0.020—0.055 mm (0.0008-—0.0022
and replace the piston and piston rings as a in)
set. Side clearance limit
c. Measure piston skirt diameter “P” with the 0.115 mm (0.0045 in)
micrometer.
Diameter
79.970—79.985 mm (3.1484—
3.1490 in)
2. Install:
e Piston ring
(into the cylinder)
TIP
Use the piston crown to level the piston ring near
8.0 mm > in) from the bottom edge of the
piston bottom of cylinder “a”, where cylinder wear is
lowest.
. foutof specification, replace the piston and
piston rings as a set. 3. Measure:
. Calculate the piston-to-cylinder clearance e Piston ring end gap
with the following formula. Out of specification + Replace the piston
ring.
Piston-to-cylinder clearance =
Cylinder bore — Piston skirt diameter
0-83
TIP 3. Measure:
The oil ring expander spacer’s end gap cannot e Piston pin bore inside diameter “b”
be measured. If the oil ring rail’s gap is exces- Out of specification + Replace the piston.
sive, replace all three piston rings.
Piston pin bore inside diameter
18.004—18.015 mm (0.7088—
Top ring 0.7093 in)
End gap limit Limit
0.50 mm (0.0197 in) 18.045 mm (0.7104 in)
2nd ring
End gap limit
0.80 mm (0.0315 in)
4. Calculate:
e Piston-pin-to-piston-pin-bore clearance
a. Bottom of cylinder
Out of specification + Replace the piston pin
b. Top of cylinder
and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
EASSO7T49
CHECKING THE PISTON PIN Piston pin bore inside diameter “b” —
Piston pin outside diameter “a”
The following procedure applies to all of the pis-
ton pins.
1. Check:
¢ Piston pin Piston-pin-to-piston-pin-bore
clearance
Blue discoloration/grooves — Replace the
0.009—0.025 mm (0.0004—0.0010
piston pin, and then check the lubrication sys-
in)
tem.
2. Measure: EAS S0750
¢ Piston pin outside diameter “a” CHECKING THE CONNECTING RODS

Out of specification — Replace the piston pin. 1. Measure:
A
¢ Crankshaft-pin-to-big-end-bearing clearance
Piston pin outside diameter Out of specification + Replace the big end
17.990—17.995 mm (0.7083- bearings.
0.7085 in)
Limit Oil clearance
17.970 mm (0.7075 in) 0.027—0.051 mm (0.0011—0.0020
in)

necting rods.
0-84
ECA13930
TIP
NOTICE
* Clean the connecting rod bolts and lubricate
Do not interchange the big end bearings and
the bolt threads and seats with molybdenum
connecting rods. To obtain the correct
disulfide oil.
crankshaft-pin-to-big-end-bearing clear-
¢ Make sure that the projection “a” on the con-
ance and prevent engine damage, the big
necting rod cap faces the same direction as the
end bearings must be installed in their origi-
“Y” mark “b” on the connecting rod.
nal positions.
* After installing the big end bearing, assemble
a. Clean the big end bearings, crankshaft the connecting rod and connecting rod cap
pins, and the inside of the connecting rods without installing them onto the crankshaft.
halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower bear-
ing into the connecting rod cap.
TIP
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
e. Tighten the connecting rod bolt while

checking that the sections shown “a” and
“b” are flush with each other by touching the
surface.
c. Put a piece of Plastigauge® “1” on the Connecting rod bolt
crankshaft pin. ZN 30 N-m (3.0 kgf-m, 22 Ib-ft)
TIP
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.
d. Assemble the connecting rod halves.

ECATB390
NOTICE
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al-
ways install new bolts.
a. Side machined face

b. Thrusting faces
0-85
f. Loosen the connecting rod bolts, remove = _

)
the connecting rod and connecting rod cap
and install these parts to the crankshaft with \
day
the big end bearing kept in the current con- Se
dition. —» |
TIP
¢ Do not move the connecting rod or crankshaft
until the clearance measurement has been
180°
completed.
e Make sure that the projection “a” on the con- SuAesae
"Y" mark “b” on the connecting rod. | If the bolt is tightened more than the speci-
* Make sure the "Y” marks "b” on the connecting fied angle, do not loosen the bolt and then re-
rods face towards the left side of the crank- tighten it. Instead, replace the bolt with anew
shaft. one and perform the procedure again.
NOTICE
j. After the installation, check that the section
shown “a” is flush with each other by touch-
ing the surface.
g. Tighten the connecting rod bolts with a

torque wrench.
Connecting rod bolt (1st)

aN 20 N-m (2.0 kgf-m, 15 Ib-ft)
h. Put a mark “1” on the corner of the connect-

ing rod bolt “2” and the connecting rod cap
“ng”. k. Remove the connecting rod and big end
bearings.
|. Measure the compressed Plastigauge®
width on the crankshaft pin. If the crank-
shaft-pin-to-big-end-bearing clearance is
out of specification, select replacement big
end bearings.
i. Tighten the connecting rod bolts further to

reach the specified angle 175—-185°.
2. Select:
¢ Big end bearing (P,—P.)
0-86
TIP
¢ The numbers “A” stamped into the crankshaft Bearing color code
web and the numbers “B” on the connecting Code 1
rods are used to determine the replacement Blue
Code 2
big end bearings sizes.
Black
e “P,”—“P..” refer to the bearings shown in the
Code 3
crankshaft illustration.
Brown
Code 4
Green
EASS0751
INSTALLING THE CONNECTING ROD AND

PISTON
necting rods and pistons.
1. Install:
¢ Big end bearing
¢« Connecting rod cap
(onto the connecting rod)
TIP
¢ Be sure to reinstall each big end bearing in its
original place.
¢ Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods
and connecting rod caps.
¢ Make sure that the projection “c” on the con-
“Y” mark “d” on the connecting rod.
For example, if the connecting rod “P,” and

the crankshaft web “P,” numbers are “5” and
“2 respectively, then the bearing size for “P,”
iS:
“P,” (connecting rod)— “P,” (crankshaft) = 5 —
2 = 3 (brown)
2. Tighten:
¢ Connecting rod bolt YEW
0-87
ECA18390 e ond ring a"
NOTICE o Top ring “5B”
Tighten the connecting rod bolts using the TIP

plastic-region tightening angle method. Al-
ways install new bolts. Be sure to install the piston rings so that the
manufacturer’s marks “a” face up.
TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
a. Replace the connecting rod bolts with new

ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with molyb-
denum disulfide oil.
c. After installing the big end bearing, assem-
ble the connecting rod and connecting rod
cap without installing them onto the crank- “ ae 4
shaft. ; : inn
d. Tighten the connecting rod bolt while tonto the respective connecting rod °2")
checking that the sections shown “a” and ° Piston en 3 _
“b” are flush with each other by touching the ¢ Piston pin clip “4” XE
surface. TIP
¢ Apply engine oil onto the piston pin.
e Make sure that the “Y” mark “a” on the connect-
ing rod faces left when the punch mark “b” on
the piston is pointing up as shown.
ow. ¢ When installing a piston pin clip, make sure
To install the big end bearing, care should be that the clip ends “c” are positioned away from
taken not to install it at an angle and the position the cutout “d” in the piston as shown in the illus-
should not be out of alignment. tration.
¢ Reinstall each piston into its original cylinder.
Pia os
° LD
a.
ZA
Side machined face
b. Thrusting faces
e. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condi-
tion.
3. Install:
* Oil ring expander “1”
* Lower oil ring rail “2”
5. Lubricate:
¢ Upper oil ring rail “3”
0-88
¢ Piston
e Piston ring Piston ring compressor
¢ Cylinder 90890-05158
(with the recommended lubricant) Piston ring compressor
YM-08037
Engine oil
6. Offset:
¢ Piston ring end gap
a,b 48
. ' 45°
c
a
| 90°
a. 2nd ring
\ 4
b. Lower oil ring rail
c. Upper oil ring rail
d. Topring
e. Oil ring expander
A. Exhaust side 9. Tighten:

7. Lubricate: ¢ Connecting rod bolt “1”
¢ Crankshaft pin
* Connecting rod big end bearing inner surface
| Engine oil |
8. Install:
¢ Connecting rod assembly “1”
(into the cylinder and onto the crankshaft pin)
¢ Connecting rod cap
TIP
(onto the connecting rod)
Tighten the connecting rod bolts using the fol-
TIP .
e While compressing the piston ring with piston owng Procecure:
ring compressor “2”, install the connecting rod a. Tighten the connecting rod bolts with a
assembly into the cylinder with the other hand. torque wrench.
¢ Make sure the “Y” marks “a” on the connecting
rods face towards the left side of the crank- Connecting rod bolt (1st)
shaft. ZN 20 N-m (2.0 kgf-m, 15 Ib-ft)
¢ Make sure that the projection “b” on the con-
necting rod cap faces the same direction as the b. Put a mark “1” on the corner of the connect-
ing rod bolt “2” and the connecting rod cap
“Y” mark “a” on the connecting rod. a”.
e Apply Molybdenum disulfide oil to the threads

and seats of the connecting rod bolt.
0-89
c. Tighten the connecting rod bolts further to

reach the specified angle 175—185°.
>
180°
EWA16610
If the bolt is tightened more than the speci-

fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890
NOTICE
d. After the installation, check that the section
shown “a” is flush with each other by touch-
ing the surface.
EWA17120
If the connecting rod and cap are not flush

with each other, remove the connecting rod
bolts and big end bearing and restart from
step (1). In this case, make sure to replace
the connecting rod bolts.
0-90
EAS201 78

Removing the crankshaft and balancer shaft

Crankcase Refer to “CRANKCASE” on page 5-74.
Connecting rod TONS" on page 580. RODS AND PIS-
1 Balancer shaft assembly 1

2 Balancer shaft journal lower bearing 3
3 Balancer shaft journal upper bearing 3
4 Crankshaft assembly 1
5 Crankshaft journal lower bearing 3
6 Crankshaft journal upper bearing 3
0-91
EASSa1 072
3. Check:
REMOVING THE BALANCER SHAFT
¢ Balancer shaft assembly
JOURNAL BEARINGS
Cracks/damage/wear — Replace the balanc-
1. Remove:
er shaft assembly and journal bearings.
¢ Balancer shaft journal lower bearing
Dirt > Clean.
(from the crankcase)
¢ Bearing
¢ Balancer shaft journal upper bearing
(from the cylinder)
4. Measure:
TIP e Balancer shaft-journal-to-balancer shaft-jour-
Identify the position of each balancer shaft journal-bearing clearance
nal bearing so that it can be reinstalled in its orig- Out of specification - Replace the balancer
inal place. shaft journal bearings.
EASS1074 Balancer shaft journal to balanc-

REMOVING THE CRANKSHAFT JOURNAL er shaft bearing clearance
BEARINGS 0.020—0.054 mm (0.0008-—0.0021
1. Remove: in)
¢ Crankshaft journal lower bearing
ECA18400
(from the crankcase)
NOTICE
¢ Crankshaft journal upper bearing
(from the cylinder) Do not interchange the balancer shaft jour-
nal bearings. To obtain the correct balancer
TIP
shaft-journal-to-balancer shaft-journal-bear-
Identify the position of each crankshaft journal ing clearance and prevent engine damage,
bearing so that it can be reinstalled in its original the balancer shaft journal bearings must be
place. installed in their original positions.
EASS1142 a. Clean the balancer shaft journal bearings,

CHECKING THE BALANCER SHAFT balancer shaft journals, and bearing por-
ASSEMBLY tions of the crankcase and cylinder.
1. Check: b. Install the balancer shaft journal upper
¢ Balancer driven gear bearings “1” and the balancer shaft assem-
Damage/wear — Replace the balancer drive bly into the cylinder.
gear and balancer shaft assembly as a set.
TIP
Excessive noise during operation — Replace
Align the projections “a” on the balancer shaft
the balancer drive gear and balancer shaft
journal upper bearings with the notches “b” in the
assembly as a set.
cylinder.
2. Measure:
¢ Balancer shaft runout
Out of specification —+ Replace the balancer
shaft assembly.
Balancer shaft runout limit

0.030 mm (0.0012 in)
c. Put a piece of Plastigauge® “2” on each

J} i
UI LL
MLC
balancer shaft journal.

Ty
TIP
Do not put the Plastigauge® over the oil hole in
the balancer shaft journal.
9-92
TIP
¢ The numbers “A” stamped into the crankcase
and the numbers “B” stamped into the balancer
shaft web are used to determine the replace-
ment balancer shaft journal bearing sizes.
e J,-J, refer to the bearings shown in the crank-
case and balancer shaft web illustration.
e If J,-J, are the same, use the same size for all
of the bearings.
d. Install the balancer shaft journal lower bear-
ings “3” into the crankcase and assemble
the crankcase and cylinder.
| ty
TIP
—k
mS
ho
GQ
—
|
qj
e Align the projections “c” of the balancer shaft
TT
journal lower bearings with the notches “d” in
the crankcase.
UE t TTT
|
¢ Do not move the balancer shaft until the clear-
ance measurement has been completed.
ah | 7
Sa
SSI
LS on. U
SSS
et
J1 J2 J3
e. Tighten the bolts to specification in the tight-
ening sequence cast on the crankcase. J1 J2 J3
Refer to “CRANKCASE” on page 5-74.
f. Remove the crankcase and the balancer ua,
TTT TT tii
shaft journal lower bearings.
g. Measure the compressed Plastigauge®
width “e” on each balancer shaft journal.
lf the balancer shaft-journal-to-balancer
MT
P
shaft-journal-bearing clearance is out of
specification, select replacement balancer
shaft journal bearings. For example, if the crankcase J, and balanc-
er shaft web J, numbers are 6 and 5 respec-
tively, then the bearing size for J, is:
J, (crankcase) — J, (balancer shaft web)
-6§6-5=
1 (blue)
5. Select:
¢ Balancer shaft journal bearing (J;—Js)
0-93
Bearing color code NOTICE

Code 1 Do not interchange the crankshaft journal
Blue bearings. To obtain the correct crankshaft-
Code 2 journal-to-crankshaft-journal-bearing clear-
Black ance and prevent engine damage, the crank-
Code 3 shaft journal bearings must be installed in
Brown their original positions.
Code 4
Green a. Clean the crankshaft journal bearings,
Code 5 crankshaft journals, and bearing portions of
Yellow the cylinder and crankcase.
b. Install the crankshaft journal upper bear-
EASS1075
ings “1” and the crankshaft into the cylinder.
CHECKING THE CRANKSHAFT
TIP
1. Check:
¢ Balancer drive gear Align the projections “a” on the crankshaft jour-
Damage/wear —> Replace the balancer drive nal upper bearings with the notches “b” in the
gear and balancer shaft assembly as a set. cylinder.
Excessive noise during operation > Replace
the balancer drive gear and balancer shaft
assembly as a set.
2. Measure:
e Crankshaft runout
Out of specification — Replace the crank-
shaft.
a Runout limit
0.030 mm (0.0012 in)
c. Put a piece of Plastigauge® “2” on each
crankshaft journal.
TIP
h Do not put the Plastigauge® over the oil hole in
te Fl A
the crankshaft journal.
a
3. Check:
¢ Crankshaft journal surface
¢ Crankshaft pin surface
* Bearing surface
scratches/wear — Replace the crankshaft. NS TY,
4. Measure: d. Install the crankshaft journal lower bearings
¢ Crankshaft-journal-to-crankshaft-journal- “3” into the crankcase and assemble the
bearing clearance crankcase and cylinder.
Out of specification — Replace the crank-
shaft journal bearings.
Journal oil clearance

0.018—0.042 mm (0.0007-0.0017
in)
0-94

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SWINGARM

Order Job/Parts to remove Q'ty Remarks

Pivot shaft protector (right)

Removing the swingarm

Order Job/Parts to remove Q'ty Remarks

Removing the swingarm

Order Job/Parts to remove Q'ty Remarks

REMOVING THE SWINGARM

CHECKING THE SWINGARM EFAS31113

CHECKING THE CONNECTING ARM

INSTALLING THE CONNECTING ARM

Connecting arm nut (frame side)

Drive chain slack (Maintenance

Order Job/Parts to remove Q'ty Remarks

Shift rod locknut (shift pedal side) Left-hand threads

Shift rod joint

Drive chain guide

Removing the drive chain

Order Job/Parts to remove Q'ty Remarks

REMOVING THE DRIVE CHAIN

Securely support the vehicle so that there is

a. Loosen the pivot shaft nut “2” so that the en-

CHECKING THE DRIVE CHAIN

15-link length limit

a. Measure the length “b” between the inner

INSTALLING THE DRIVE SPROCKET

¢ While applying the rear brake, tighten the drive

CHECKING THE DRIVE SPROCKET

INSTALLING THE DRIVE CHAIN

1. Drive chain roller

CHECKING THE REAR WHEEL SPROCKET

4. Fit the space “a” between the side plates of

Shift rod locknut (shift arm side)

d. Make sure the installed shift rod length is

Drive chain slack (Maintenance

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VALVES AND VALVE SPRINGG...........ssscssssssssssssessccnscecsessesccecnessesssscansssenes 5-38

GENERATOR AND STARTER CLUTCH..............ccccsccssenseeseeesenseeeaseaaeneeneaes 5-45

SHIFT SHAFT. ........cccccssssecccssecsscsnssessccaneessccnssscncnnesseseneaseescsnesessocnaecesosaceeseseas 5-65

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PENG ais oststie reise ence ve wes eerseeseseawademssenaetenseenanenssuecessadeuseuessresuueassanendenes 5-74

CONNECTING RODS AND PISTONS. ..........cccccscescssnseeseensaeeeeeeseeseeeaeeneesenneas 5-80

LUBRICATION SYSTEM CHART AND DIAGRAMS

ENGINE OIL LUBRICATION CHART

Timing chain tensioner

Crankcase and cylinder (left side view)

Balancer shaft assembly

Oil pump (bottom view)

Oil pressure switch

Camshaft (top view)

Crankshaft (front view)

Crankshaft and transmission (top view)

Balancer shaft assembly

Before removing the spark plugs, use com-

Order Job/Parts to remove Q'ty Remarks

Disconnecting the leads and hoses

Order Job/Parts to remove Remarks

Disconnecting the leads and hoses

Order Job/Parts to remove Q'ty Remarks

Disconnecting the leads and hoses